Student Assignments for EV-400_053287 EV High-Voltage Safety Trainer 95-EV-400_REVB © ConsuLab Educatech Inc, 2025. All rights reserved. 95-EV-400 Table of contents 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 2 Table of contents Section 1 The Basics of an EV The Basics of an EV 5 Safety 6 Section 2 Safety when working on an EV Safety when working on an EV 8 SA-1 — Checking your PPE 10 SA-2 — Meter Use 11 SA-3 — Introduction to the EV-400 12 SA-4 — Measuring Various Voltages on the EV-400 14 SA-5 — Safety Devices 15 Safety when Working on an EV — Exam 16 Section 3 Intro to High Voltage Intro to High Voltage 19 High Voltage — Quiz 21 SA-6 — Introduction to the EV-400 Batteries 23 SA-7 — Introduction to the EV-400 Contactors 25 SA-8 — High Voltage Distribution 27 SA-9 — The HV Inverter 28 SA-10 — Measuring 3-Phase AC 30 SA-11 — DC-to- DC Converter 32 SA-12 — Other HV Components 34 Section 4 Intro to HV Interlock Circuit Intro to HV Interlock Circuit 37 SA-13 — Connections and the HVIL 41 SA-14 Connectors and the HVIL 42 SA-15 The HVIL’s Applied Voltage 43 95-EV-400 Table of contents 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 3 © ConsuLab Educatech Inc, 2025. All rights reserved. No part of this work may be reproduced or transmitted in any form by any means, electronic, mechanical, including photocopying and recording, or by any information storage or retrieval system, without written permission from the publisher. Printed in Canada. The content of this manual is applicable to models 053287 and above. SA-16 — The HVIL’s Voltage 45 SA-17 — The HVIL’s Applied Voltage under Load 47 SA-18 — The HVIL’s Voltage Drops 1 49 SA-19 — The HVIL’s Voltage Drops 2 51 SA-20 — The HVIL’s Voltage Drops with an Open Circuit 1 53 SA-21 — The HVIL’s Voltage Drops with an Open Circuit 2 55 SA-22 — The HVIL’s Voltage Drops with Current Flowing 57 Interlock Loop Quiz 59 Section 5 Introduction to Fault Diagnosis and Isolation Testing Introduction to Fault Diagnosis and Isolation Testing 62 Function of Loss of Isolation (LOI) 63 Understanding Loss of Isolation (LOI) in Electric Vehicles: Definition, Testing, and Safety Measures 63 SA-23 — Fault Diagnosis 1 65 SA-24 — Fault Diagnosis 2 67 SA-25 — Fault Diagnosis 3 69 SA-26 — Fault Diagnosis 4 71 SA-27 — Isolation Testing 73 Section 6 Optional Assignments SA-28 — Live-Dead-Live Testing 76 SA-29 — Section or Component Identification 78 Educational Schematics EV-400 Educational Schematic — HVIL only 82 EV-400 Educational Schematic — HV only 83 EV-400 Educational Schematic — HV & HVIL 84 consulab.com info@consulab.com 4 95-EV-400 Section 1 — The Basics of an EV Section 1 The Basics of an EV consulab.com info@consulab.com 5 95-EV-400 Section 1 — The Basics of an EV The Basics of an EV Electric Vehicles (EV) are relatively simple to understand. All EV’s have some common components. These are: 1. High Voltage battery 2. DC-to-AC inverter 3. DC-to-DC converter 4. AC Motor 5. Contactors Let’s look at these components individually and relate them to the EV-400 High-Voltage Safety Trainer. Since we require a large amount of current to run a vehicle, the High Voltage Battery is substantial.In many vehicles it runs the length of the vehicle from front wheels to rear wheels. It adds a substantial amount of weight to a vehicle. The voltage of the battery varies and might be higher than 600 volts. The EV-400 runs on 400 volts which you will be able to measure with the correct meter. This is 400V direct current (DC), from the battery, which presents a problem. Most EV motors run on Alternate Current (AC). So, the DC of the battery must be transformed into AC for the motor. This will be done by the DC-to-AC Inverter and this high voltage AC will be delivered through a controller to the motor. The object of the controller is to allow for variable AC voltage frequency based on the driver’s demands. If the driver increases pressure on the accelerator pedal, a signal goes to the controller to increase the frequency to the motor, and it spins faster. Additionally, since most vehicles use 12V components, like lights, radio, blower motors, window motors, etc., the 400VDC of the battery will be converted down to usually 14 VDC through the use of a DC-to-DC Converter. Some vehicles have a 12V battery, which is charged with current from the DC-to-DC converter. All power to the vehicle from the battery has to be able to be turned on or off easily. This is done by the contactors. Usually there are three: a positive, a negative and a pre-charge. During the student assignments you will have a detailed look at the contactors. The last piece of the puzzle is the AC drive motor. On the EV-400, it runs on 400 volts with variable frequency. The lower the frequency the lower speed and torque (twisting effort) developed. If the driver increases the pressure on the accelerator pedal, the frequency increases developing more speed and torque. Motors draw the most power when they are stopped. This is the reason why most EV’s have great acceleration from a dead stop. The inverter on the EV-400 controls the frequency delivered to the motor. One of the first things we will do with the EV-400 is see how it functions through a series of simple lab activities. consulab.com info@consulab.com 6 95-EV-400 Section 1 — The Basics of an EV Safety A frequent question asked of technicians is, “ Since the vehicle has a 400V battery, isn’t there danger to the driver of technician? ” The best answer is a resounding “ YES! ” Can 400 VDC kill you? YES! Do you need safety training? YES! Do you need to protect yourself from electrical shock? YES! There are a large number of circuits and components on an EV that are designed to protect the technician from high voltage, whether it be DC or AC. At first, high voltage wiring is colored orange when the voltage exceeds 60 volts. Note: On the EV-400 orange also signifies high voltage which is around 400 V. EV’s have circuits that are designed to protect the technician. One of these is the High Voltage Interlock Loop (HVIL). We will examine this circuit in depth prior to doing the labs associated with it. It is typically a low voltage series circuit with one path through the high voltage components. Any problems sensed will not allow the Interlock loop circuit to close, effectively not allowing the contactors to close. This eliminates high voltage leaving the battery. The HVIL will also have a First Responder loop that can be either opened or cut to open in the event of an accident. Technicians who have to work on the vehicle will either open the HVIL and/or remove the Manual Service Disconnect. At no time should anyone be near an EV without having Personal Protection Equipment (PPE) on. consulab.com info@consulab.com 7 95-EV-400 Section 2 — Safety when working on an EV Section 2 Safety when working on an EV consulab.com info@consulab.com 8 95-EV-400 Section 2 — Safety when working on an EV Safety when working on an EV There is the feeling among some technicians that a vehicle cannot kill you. This may have been true with Internal Com- bustion Engine vehicles BUT, nothing is farther from the truth with Electric Vehicles. The orange cables seen on EV’s attest to the high voltage present. Orange is used when voltages are higher than 60 V. The EV-400 has voltages near 400 V and, as such, uses the orange cable or diagrams where 400 V is present. While you work on the EV-400 you will be required to wear protective gloves and eye protection. The gloves will be red in color and have a “0” rating. Note: You will wear leather gloves over the rubber glove. This increases the insulating property of the rubber glove and protects them from tears or holes. Your instructor will show you how to inspect the gloves prior to using them. It will take you a bit of time to get used to using the gloves while working on the EV-400, so don’t get frustrated and take them off. Technicians doing any work near the high voltage of an EV must wear personal protective equipment ALL THE TIME. Get used to PPE since it is designed to protect you! Safety when working on an EV There is the feeling among some technicians that a vehicle cannot kill you. This may have been true with Internal Combustion Engine vehicles BUT, nothing is farther from the truth with Electric Vehicles. The orange cables seen on EV’s attest to the high voltage present. Orange is used when voltages are higher than 60V. The EV-400 has voltages near 400 V and, as such, uses the orange cable or diagrams where 400 V is present. While you work on the EV-400 you will be required to wear protective gloves and eye protection. The gloves will be red in color and have a “0” rating. Note: You will wear leather gloves over the rubber glove. This increases the insulating property of the rubber glove and protects them from tears or holes. Your instructor will show you how to inspect the gloves prior to using them. It will take you a bit of time to get used to using the gloves while working on the EV-400, so don’t get Safety when working on an EV There is the feeling among some technicians that a vehicle cannot kill you. This may have been true with Internal Combustion Engine vehicles BUT, nothing is farther from the truth with Electric Vehicles. The orange cables seen on EV’s attest to the high voltage present. Orange is used when voltages are higher than 60V. The EV-400 has voltages near 400 V and, as such, uses the orange cable or diagrams where 400 V is present. While you work on the EV-400 you will be required to wear protective gloves and eye protection. The gloves will be red in color and have a “0” rating. Note: You will wear leather gloves over the rubber glove. This increases the insulating property of the rubber glove and protects them from tears or holes. Your instructor will show you how to inspect the gloves prior to using them. It will take you a bit of time to get used to using the gloves while working on the EV-400, so don’t get consulab.com info@consulab.com 9 95-EV-400 Section 2 — Safety when working on an EV Meters and meter leads must also be EV safe. The Klein ET600 meter supplied with the EV-400 is an Insu- lation Tester specially designed for vehicles with on-board high voltages and conforms to EN61010 CAT III (1000 volts) and CAT IV (600 volts). The insulation test function tests the insulation of the high voltage wires and components found on high-voltage vehicles. You will use the insulation test function in the High Voltage Section of this student manual. You should only use meter leads that display 1000V CAT III and 600V CAT IV (left picture). Additionally, your meter should display the same 1000V CAT III and 600V CAT IV (right picture). frustrated and take them oN. Technicians doing any work near the high voltage of an EV must wear personal protective equipment ALL THE TIME. Get used to PPE since it is designed to protect you! Meters and meter leads must also be EV safe. The Klein ET600 meter supplied with the EV-400 is an Insulation Tester specially designed for vehicles with on-board high voltages and conforms to EN61010 CAT III (1000 volts) and CAT IV (600 volts). The insulation test function tests the insulation of the high voltage wires and components found on high-voltage vehicles. You will use the insulation test function in the High Voltage Section of this Student Guide. You should only use meter leads that display 1000V CAT III and 600V CAT IV (left picture). Additionally, your meter should display the same 1000V CAT III and 600V CAT IV (right frustrated and take them oN. Technicians doing any work near the high voltage of an EV must wear personal protective equipment ALL THE TIME. Get used to PPE since it is designed to protect you! Meters and meter leads must also be EV safe. The Klein ET600 meter supplied with the EV-400 is an Insulation Tester specially designed for vehicles with on-board high voltages and conforms to EN61010 CAT III (1000 volts) and CAT IV (600 volts). The insulation test function tests the insulation of the high voltage wires and components found on high-voltage vehicles. You will use the insulation test function in the High Voltage Section of this Student Guide. You should only use meter leads that display 1000V CAT III and 600V CAT IV (left picture). Additionally, your meter should display the same 1000V CAT III and 600V CAT IV (right Use ONLY leads that come with CAT III and CAT IV meters. Do not interchange leads from a different meter since they might not be rated for the EV tests you are doing. Remember that to use the EV 400, you must be wearing protective gloves and safety glasses. When you are working on a live vehicle additional PPE is required. This includes arc shields for your face, protective aprons for your body and special shoes. When we cover isolation faults we will discuss the need for additional safety equipment. An isolation fault occurs when the protective insulation breaks down allowing high voltage to be present where it should not be. You will find additional safety equipment and procedures in the High Voltage Distribution section of this student manual. During the labs and when you work on an actual EV, you will practice Live-Dead-Live testing for safety porposes. Prior to working on a high voltage circuit you will first test the meter on a known voltage like the vehicle 12V battery. This is the “Live” portion of the test procedure. We now know the meter is functional. Next, we test after the contactors to ensure that they are open or “dead”. Lastly we again test the meter on a live circuit. Test the meter, measure a hopefully dead circuit and then test the meter again. Only after following this procedure can you be sure the High Voltage circuit will not harm you. Practice Live-Dead-Live testing every time you will be working on an Electric Vehicle. It will ensure your safety. frustrated and take them oN. Technicians doing any work near the high voltage of an EV must wear personal protective equipment ALL THE TIME. Get used to PPE since it is designed to protect you! Meters and meter leads must also be EV safe. The Klein ET600 meter supplied with the EV-400 is an Insulation Tester specially designed for vehicles with on-board high voltages and conforms to EN61010 CAT III (1000 volts) and CAT IV (600 volts). The insulation test function tests the insulation of the high voltage wires and components found on high-voltage vehicles. You will use the insulation test function in the High Voltage Section of this Student Guide. You should only use meter leads that display 1000V CAT III and 600V CAT IV (left picture). Additionally, your meter should display the same 1000V CAT III and 600V CAT IV (right consulab.com info@consulab.com 10 95-EV-400 Section 2 — SA-1 SA-1 — Checking your PPE Name : Group : Date : You should put your answers directly on this page. Objective: To ensure that your PPE, specifically your high voltage gloves, are still within date and capable of protecting you while you work on an EV or the EV-400 trainer. Required Equipment: Set of Class 0 gloves. Procedure: Follow the procedure found in the following QR Code. Use your phone to follow the QR Code. 1. Did the gloves pass the visual inspection? Yes No 2. Did the gloves pass the air test? Yes No 3. What is the date on the gloves? . If a QR Code is present on the gloves scan it. What additional information did you receive? 4. What is the tag color? Note: The gloves can be a variety of colors. What denotes the class is the tag, found near the cuff? color. 5. What class should the gloves be? 6. What class are these gloves? 7. Explain the significance of these tests? Instructor grade : Instructor Signature : Comments : consulab.com info@consulab.com 11 95-EV-400 Section 2 — SA-2 SA-2 — Meter Use Name : Group : Date : You should put your answers directly on this page. Objective: To look at the meter that you will use and determine its capability. Required equipment: Klein ET600 Meter. Procedure: 1. Check out the Klein ET600 meter that was supplied with the EV-400 Trainer. 2. On the back of the meter is a small QR code. Use your phone and scan it. A site will open up that will give you all the necessary information on the meter. Use the information to fill in the following questions: 3. What CAT rating is this meter? and 4. What voltage is the meter rated “safe” for? and 5. Look at the front lower right corner of the meter. What CAT leads are to be used? and 6. Look at the end of the meter leads on the small boot that covers the measurement end of the leads. What CAT are these leads? and Note: The safety rating of these meter leads is only with the boots over the end. If you remove the boots, the leads are no longer CAT certified. 7. What is the significance of the CAT rating? 8. Explain your results to your instructor. Instructor grade : Instructor Signature : Comments : consulab.com info@consulab.com 12 95-EV-400 Section 2 — SA-3 SA-3 — Introduction to the EV-400 Name : Group : Date : You should put your answers directly on this page. Objective: To develop a working knowledge of how the EV-400 (EV High-Voltage Safety trainer) work. Required equipment: EV-400, power supply, High Voltage gloves and 110V outlet. Procedure: 1. Plug in the EV-400 power supply into the left side of the trainer. 2. Plug in the power supply to the 110V outlet: 3. Perform the High Voltage glove test SA- 1. 4. With gloved hand, turn on the unit with the switch in the upper left corner. The green light should illuminate. There should be a red light near the key fob holder. 5. Place the key fob into the key fob holder. The orange ready light should be illuminated. 6. Ensure that all switches are closed labeled SW1, SW2, SW3, SW4, SW10, SW11 and SW12. 12 VDC Battery switches should be up, Heat switches to the left. P, R, D switch in P (park). 7. Hold the Brake switch down while you push the Ignition switch. Note: High Voltage is present now in the trainer. Make sure you have PPE on! 8. At this point the ignition light should be on, SMR 2 and SMR 3 should be lit. 9. What does the main meter read? 10. Is this AC or DC Volts? 11. Turn on Heat switch. What happens? 12. Turn on AC switch. What happens? consulab.com info@consulab.com 13 95-EV-400 Section 2 — SA-3 13. Move the gear selector to D and push the accelerator button. What happens? 14. Move the gear selector to R and push the accelerator button. What happens? 15. Move the gear selector to the P (park) position, turn off AC and Heat. Push the Ignition button. This effectively shuts the trainer down. 16. Switch the power button to off. 17. Show your instructor your results and be prepared to explain how the trainer functions. Instructor grade : Instructor Signature : Comments : consulab.com info@consulab.com 14 95-EV-400 Section 2 — SA-4 SA-4 — Measuring Various Voltages on the EV-400 Name : Group : Date : You should put your answers directly on this page. Objective: The EV-400 gives the ability to measure various voltages, both alternating current (AC)and direct current (DC). In this lab we will look at the DC voltages available. Required equipment: EV-400, Klein ET600 meter and PPE (gloves and safety glasses). Procedure: In this lab you will power up the EV-400 with your PPE (gloves and safety glasses) in place. 1. Power up the EV-400. With it in P (park), take voltage readings and record. Maintain meter polarity correctly. The positive meter lead in the positive socket and the negative lead in the negative socket. We will look at the “why” of the voltages in the HV section of the student activities. 2. HV15 — HV3: VDC 3. HV16 — HV4: VDC 4. HV3 — HV4: VDC 5. HV5 — HV6: VDC 6. HV7 — HV8: VDC 7. HV9 — HV10: VDC 8. HV11 — HV12: VDC 9. HV13 — HV14: VDC 10. DC1 — DC2: VDC 11. Show you instructor your results and be prepared to discuss the readings. Instructor grade : Instructor Signature : Comments : consulab.com info@consulab.com 15 95-EV-400 Section 2 — SA-5 SA-5 — Safety Devices Name : Group : Date : You should put your answers directly on this page. Objective: To look at two of the safety devices that all EV’s have and see their purpose. Required equipment: EV-400. Procedure: Plug in the EV-400 and power it up. 1. What does the voltmeter on the front of the EV-400 read? V 2. Remove the service disconnect. Note: It has two latches and you must depress both. 3. What happened to the system voltage? Note: The service disconnect is in the High Voltage and the High Voltage Interlock Loop circuit diagrams since both volt- ages are present. 4. Show the service disconnect to your instructor. Instructor signature: 5. Plug the service disconnect back in making sure the latch is clipped. 6. Re-power up the EV-400. Does the display show voltage again? V 7. Unplug the First Responder Loop. What happens? 8. Show your instructor what happens when the loop is opened. 9. Using the EV-400 Distribution and the HVIL Loop diagrams, explain where these two disconnects are and what hap- pens when they are disconnected or opened. Show your instructor. Instructor grade : Instructor Signature : Comments : consulab.com info@consulab.com 16 95-EV-400 Section 2 — Safety when working on an EV — Exam Safety when Working on an EV — Exam Note: You must achieve a 100% correct score to be able to go on to the next sections of the EV-400 Student Manual and/or work on a live Electric Venicle. You should put your answers directly on this page. Circle the correct letter when required. Name : Group : Date : 1. Two technicians are discussing insulated gloves. Technician A states that the gloves should be a minimum of 0 rated. Technician B states that the gloves should be red in color. Who is correct? A. Only Technician A B. Only Technician B C. Both Technician A and Technician B D. Neither Technician A nor Technician B 2. Orange cables are seen on a vehicle. This indicates that... A. Voltages present are less than 60 volts B. Current present is less than 5 amps C. Voltages present are in excess of 60 volts D. Safety gloves are not necessary 3. Technician A states that prior to using EV gloves, they should be tested and inspected. Technician B states that leather gloves should be placed over the rubber gloves to protect against tears or holes. Who is correct? A. Only Technician A B. Only Technician B C. Both Technician A and Technician B D. Neither Technician A nor Technician B 4. Meters and meter leads must be CAT and CAT to be used on an Electric Vehicle of the EV-400. A. II and III B. Any rating as long as it is CAT C. III and IV D. IV and V consulab.com info@consulab.com 17 95-EV-400 Section 2 — Safety when working on an EV — Exam 5. A Technician approached an EV. He should... A. Assume it to be live and wear PPE B. Test High Voltage circuits to ensure they are safe C. Remove the Disconnect or First Responder loop D. All of the above 6. EV safety gloves are tested... A. Annually B. Once during the life of the gloves C. Never D. Every 6 months 7. What is the purpose of the “dead” in a live-dead-live test? A. Make sure the High Voltage circuit does not have lethal voltages B. Determine why the vehicle will not start C. Allow the use of a scanner D. Make sure the ignition switch is on 8. Two technicians are discussing the First Responder loop. Technician A states that it should be cut or opened any- time service is performed on the vehicle. Technician B states that in case of an accident, a fireman will cut the loop to disable the High Voltage circuits on the vehicle. Who is correct? A. Only Technician A B. Only Technician B C. Both Technician A and Technician B D. Neither Technician A nor Technician B 9. The High Voltage of the vehicle is isolated from the vehicle’s... A. Drive motor B. Disconnect C. Chassis ground D. Interior heater 10. An isolation test done on a drive motor shows low resistance to chasis ground. This indicates that... A. The insulation has broken down B. All is normal C. A shorted connector is present D. Safety gloves are not necessary Instructor grade : Instructor Signature : Comments : consulab.com info@consulab.com 18 95-EV-400 Section 3 — Intro to High Voltage Section 3 Intro to High Voltage consulab.com info@consulab.com 19 95-EV-400 Section 3 — Intro to High Voltage Intro to High Voltage Most vehicles and the EV-400 will use multiple batteries wired in series to get the high voltage neces- sary. In the case of the EV-400, we have two 200VDC batteries. EV Vehicles use various modules to control or deliver the high voltage to the drive motor(s) and/or components such as cabin heat, AC compressor, etc. Using the EV-400 as an example, and with the unit off, follow the circuit beginning at the batteries (2). Each battery produces about 200 volts and if they are wired in series we can get the 400 VDC re- quired. The main control of the high voltage are the contactors. These very heavy duty relays or switches will allow the current from both batteries to flow to the components that need current. The high voltage and current have their own positive and negative circuits that are separate from chassis ground. You should have noticed that the three contactors have a sequence. First SMR1 blinks. This is a test of the contactor function. Next SMR3 and SMR1 will turn on. SMR3 is the negative side of the High Voltage. To prevent a surge of current, SMR2 remains open and SMR1 acts as a reduced voltage relay called a Pre- Charge Contactor. Next SMR2 closes connecting the batteries to the positive of the HV circuit. The last thing is the pre-charge contactor opens and the ready light lights. On a vehicle this all happens very fast. We have slowed the action of the contactors so you can observe their sequence and function. Once the ready light is lit the meter in the High Voltage Distribution Module will show system voltage which on the EV-400 is around 400 VDC. If you follow the orange lines, indicating wires, you will arrive at the High Voltage Distribution section. The cable labeled C1 and C2 will bring the High Voltage to the Inverter. The inverter is the heart of the drive system of an EV. It will convert the 400 VDC over to 400 VAC which the motor will use. AC is more efficient than DC and is more frequently used to power the motors that will drive the vehicle down the road. consulab.com info@consulab.com 20 95-EV-400 Section 3 — Intro to High Voltage From here the HV can be delivered to four different modules. The Inverter (DC-to-AC), the Cabin Heater, the A/C Compressor, and the DC-to-DC Converter. They each have different functions. The DC-to-DC Converter will change the 400 VDC into about 14 VDC to charge the battery. Any additional accessories that require high voltage will be connected to the High Voltage Distribution. These include the Cabin Heater and the A/C Compressor on the EV-400. Now that we have a simple idea as to the function of the High Voltage system (HV), we can move into the student activities. consulab.com info@consulab.com 21 95-EV-400 Section 3 — High Voltage — Quiz High Voltage — Quiz Name : Group : Date : You should put your answers directly on this page. Circle the correct letter. 1. The High Voltage on most vehicles comes from: A. Multiple batteries in a series/parallel wiring B. 4 – 100VAC batteries wired in series C. Large capacitors that store current D. DC-to-AC Inverter 2. Two technicians are discussing the High Voltage in many vehicles. Technician A states that it is common to be at 400 V or higher. Technician B states that usually one High Voltage cell is used. Who is correct? A. Only Technician A B. Only Technician B C. Both Technician A and Technician B D. Neither Technician A nor Technician B 3. 4 – 300Ω resistors are wired in series with 12 volts applied. The voltage drop across each resistor will be? A. 12 V B. 8 V C. 6 V D. 3 V 4. The purpose of the inverter is to... A. Change the voltage available to battery voltage B. Turn the DC battery voltage into AC to run the motor C. Filter the DC so it is pure enough to run the drive motor D. Allow the 12V battery to charge 5. The purpose of the DC-to-DC converter is to... A. Change the voltage available to battery voltage B. Turn the DC battery voltage into AC to run the motor C. Filter the DC so it is pure enough to run the drive motor D. Allow the 12V battery to charge consulab.com info@consulab.com 22 95-EV-400 Section 3 — High Voltage — Quiz 6. The First Responder’s loop will... A. Shut down the high voltage B. Change the AC into DC C. Communicate with First Responders the status of the vehicle D. Turn off the DC-to-DC converter 7. An Electric Vehicle is in the shop for routine electrical service. Technician A states the key should be removed and moved far from the vehicle or put in a metal box. Technician B states that the Service Disconnect should be opened and removed from the vehicle. Who is correct? A. Only Technician A B. Only Technician B C. Both Technician A and Technician B D. Neither Technician A nor Technician B 8. 400 VDC is measured at the A/C compressor. 12.6 volts is measured at the vehicle battery. This indicates... A. The DC-to-AC inverter is not functioning B. The DC-to-DC converter is not functioning C. The First Responder’s loop is open D. The Service disconnect is open 9. A DTC is set for an open High Voltage contactor. This will... A. Allow the vehicle to be driven but only slowly < B. Set only the main drive motor to function C. Start charging of the 12V battery D. Shut down the vehicle completely 10. The negative contactor is shorted. This will... A. Allow the vehicle to be driven but only slowly B. Set only the main drive motor to function C. Start charging of the 12V battery D. Shut down the vehicle completely Instructor grade : Instructor Signature : Comments : consulab.com info@consulab.com 23 95-EV-400 Section 3 — SA-6 SA-6 — Introduction to the EV-400 Batteries Name : Group : Date : You should put your answers directly on this page. Objective: To develop a working knowledge of how the EV-400 (EV High-Voltage Safety trainer) develops high voltage. Required equipment: EV-400, power supply, High Voltage gloves, 110V outlet, Klein ET600 DMM and wiring diagrams. Procedure: 1. Plug in the EV-400 power supply into the left side of the trainer. 2. Plug in the power supply to the 110V outlet. 3. Perform the High Voltage glove test SA-1. 4. With gloved hand, turn on the unit with the switch in the upper left corner. The green light should illuminate. There should be a red light near the key fob holder. 5. Place the key fob into the key fob holder. The orange ready light should be illuminated. 6. Ensure that all switches are closed labeled SW1, SW2, SW3, SW4, SW10, SW11 and SW12. 12VDC Battery switches should be up and AC, Heat switches to the left. P, R, D switch in P (park). 7. Use the wiring diagram and find the 2 batteries. What voltage does the diagram show each to be? V. Is this AC or DC ? 8. What test points should allow you to measure each battery? and and 9. Measure and record the test points in step #8: V and V 10. Is there two test points that will allow you to read the combined voltage of both batteries? Yes No 11. If yes to step #10 what are the test points? and 12. Measure the voltage at the test points from step #10 and record the reading here: V 13. Disconnect the service disconnect. What happened to your reading in step #12? consulab.com info@consulab.com 24 95-EV-400 Section 3 — SA-6 14. Why for step #13? 15. How does the EV-400 develop the approximately 400 V when functioning? 16. Show your instructor your results and be prepared to explain how the trainer functions. Instructor grade : Instructor Signature : Comments : consulab.com info@consulab.com 25 95-EV-400 Section 3 — SA-7 SA-7 — Introduction to the EV-400 Contactors Name : Group : Date : You should put your answers directly on this page. Objective: To develop a working knowledge of how the EV-400 (EV High-Voltage Safety trainer) contactors function. Required equipment: EV-400, power supply, High Voltage gloves, 110V outlet, Klein ET600 DMM and wiring diagrams. Procedure: 1. Plug in the EV-400 power supply into the left side of the trainer. 2. Plug in the power supply to the 110V outlet. 3. Perform the High Voltage glove test SA- 1. 4. With gloved hand, turn on the unit with the switch in the upper left corner. The green light should illuminate. There should be a red light near the key fob holder. 5. Place the key fob into the key fob holder. The orange ready light should be illuminated. 6. Ensure that all switches are closed labeled SW1, SW2, SW3, SW4, SW10, SW11 and SW12. 12VDC Battery switches should be up and AC, Heat switches to the left. P, R, D switch in P (park). Note: You may have to do the following sequence a few times to identify the sequence of the contactors 7. Place your finger on the brake switch and push the ignition. 8. What happened first at the three contactor lights? 9. What happened second at the three contactor lights? 10. What happened third at the three contactor lights? consulab.com info@consulab.com 26 95-EV-400 Section 3 — SA-7 11. What happened fourth at the three contactor lights? 12. When did the ready light come on? 13. Based on the HV wiring diagram, what sockets should have High Voltage coming out of the Contactors? and 14. Measure at the step #13 sockets. What voltage is present? V AC or DC ? 15. Why did the SMR3 light blink first? What does this indicate? You may refer to the Intro to High Voltage pages. 16. Write the sequence of the lights here A. B. C. D. 17. Show your instructor your results and be prepared to explain how the contactors function. Instructor grade : Instructor Signature : Comments : consulab.com info@consulab.com 27 95-EV-400 Section 3 — SA-8 SA-8 — High Voltage Distribution Name : Group : Date : You should put your answers directly on this page. Objective: To develop a working knowledge of how the EV-400 (EV High-Voltage Safety trainer) distributes the High Volt- age. Required equipment: EV-400, power supply, High Voltage gloves, 110V outlet, Klein ET600 DMM and wiring diagrams. Procedure: 1. Plug in the EV-400 power supply into the left side of the trainer. 2. Plug in the power supply to the 110V outlet. 3. Perform the High Voltage glove test SA- 1. 4. With gloved hand, turn on the unit with the switch in the upper left corner. The green light should illuminate. There should be a red light near the key fob holder. 5. Place the key fob into the key fob holder. The orange ready light should be illuminated. 6. Ensure that all switches are closed labeled SW1, SW2, SW3, SW4, SW10, SW11 and SW12. 12VDC Battery switches should be up and AC, Heat switches to the left. P, R, D switch in P (park). 7. Use the wiring diagram to identify the source of High Voltage coming from the Contactors. 8. What socket delivers the High Voltage to the distribution network? HV and HV 9. Measure the voltage present at the identified sockets in step #8: V 10. Is this voltage AC or DC? 11. Identify the high Voltage sockets that should have High Voltage in the HV Distribution: HV and HV 12. Measure the voltage present at the identified sockets in step #11: V 13. Is this voltage AC or DC? 14. From the HV Distribution, what components or modules have HV available? 15. Show your instructor your results and be prepared to explain how the HV Distribution functions. Your answers should include the voltage path for the HV. Instructor grade : Instructor Signature : Comments : consulab.com info@consulab.com 28 95-EV-400 Section 3 — SA-9 SA-9 — The HV Inverter Name : Group : Date : You should put your answers directly on this page. Objective: To develop a working knowledge of how the EV-400 (EV High-Voltage Safety trainer) uses the inverter. Required equipment: EV-400, power supply, High Voltage gloves, 110V outlet, Klein ET600 DMM and wiring diagrams. Procedure: 1. Plug in the EV-400 power supply into the left side of the trainer. 2. Plug in the power supply to the 110V outlet. 3. Perform the High Voltage glove test SA- 1. 4. With gloved hand, turn on the unit with the switch in the upper left corner. The green light should illuminate. There should be a red light near the key fob holder. 5. Place the key fob into the key fob holder. The orange ready light should be illuminated. 6. Ensure that all switches are closed labeled SW1, SW2, SW3, SW4, SW10, SW11 and SW12. 12VDC Battery switches should be up and AC, Heat switches to the left. P, R, D switch in P (park). 7. Use the wiring diagram to identify the source of High Voltage coming from the HV Distribution. 8. Measure the HV available at the at the HV Distribution: V 9. Is this voltage AC or DC? 10. Use the search function on your phone and look up “Define High Voltage Inverter” 11. Write the definition here. Note: you may simplify the definition. 12. Using the wiring diagram, follow the DC into the inverter and note which sockets should have the incoming DC avail- able: HV and HV 13. Use the meter and measure the voltage at the identified sockets: VDC 14. Switch your meter over to AC and measure at either of the three motor sockets: VAC consulab.com info@consulab.com 29 95-EV-400 Section 3 — SA-9 15. What did you have to do to get AC voltage at the three motor sockets? 16. Use your phone and search Wikipedia for three phase electric power. Read about the 4 wires or lines. Note: On the EV-400 the neutral wire is identified as “N” and the three phase lines are labeled “U, V and W”. The voltage between any phase and neutral will be 120 degrees apart from the other lines. With a 3-channel scope, you will be able to see the crossing of the voltages from each line, first positive, then negative. Each rotation of the motor (360 degrees) will have each line 120 degrees apart. SA-10 will go into the use of the scope. Answer the following questions: A. What component changes the DC into AC? B. What does 3-phase mean? C. What does the main drive motor run on AC or DC ? D. If the voltage to the motor increase, what does the current do? Increases or Decreases E. What do the lights on the motor of the EV-400 indicate? F. Pulse the motor accelerator on for 1 sec. off for one sec. What does the AC meter read? VAC G. Hold the accelerator down continuously. What does the meter read? VAC 17. Show your instructor your results and be prepared to explain how the HV Inverter functions. Your answers should include the voltage path for the HV and the 3-phase motor. Instructor grade : Instructor Signature : Comments : consulab.com info@consulab.com 30 95-EV-400 Section 3 — SA-10 SA-10 — Measuring 3-Phase AC Name : Group : Date : You should put your answers directly on this page. Objective: To develop a working knowledge of how the EV-400 (EV High-Voltage Safety trainer) uses the Inverter to gen- erate 3-phase AC Required equipment: EV-400, power supply, High Voltage gloves, 110V outlet, Klein ET600 DMM and wiring diagrams. Procedure: 1. Plug in the EV-400 power supply into the left side of the trainer. 2. Plug in the power supply to the 110V outlet. 3. Perform the High Voltage glove test SA- 1. 4. With gloved hand, turn on the unit with the switch in the upper left corner. The green light should illuminate. There should be a red light near the key fob holder. 5. Place the key fob into the key fob holder. The orange ready light should be illuminated. 6. Ensure that all switches are closed labeled SW1, SW2, SW3, SW4, SW10, SW11 and SW12. 12VDC Battery switches should be up and AC, Heat switches to the left. P, R, D switch in P (park). 7. Power up the EV-400. What voltage is available to the Inverter? V Is it AC or DC ? 8. Use a Digital Storage Oscilloscope with at least 3 channels. Connect all three negatives to the N terminal. Connect each channel input to one of each line (U, V, and W). 9. Set your voltage so that 0 V is in the middle of the screen and you can read at least 15V positive and 15V negative. Don’t hesitate to ask your instructor about this set up. 10. Set your DSO to about 500 ms per division. Note you may have to change the time base to get full patterns on the screen once the motor is spinning. 11. Put the EV-400 in drive and push down and hold the accelerator down. You should have three AC patterns on the screen. Adjust the time base until there are full patterns, with full positive and full negative wave- forms. Once you have the pattern on the screen, press the hold button. consulab.com info@consulab.com 31 95-EV-400 Section 3 — SA-10 12. If you have print capability in your shop print the pattern. If printing is not available, draw the pattern below. 0 Phase 1 Phase 2 Phase 3 13. Show your instructor your results and be prepared to explain how the inverter works and generates 3-phase AC. Instructor grade : Instructor Signature : Comments : consulab.com info@consulab.com 32 95-EV-400 Section 3 — SA-11 SA-11 — DC-to- DC Converter Name : Group : Date : You should put your answers directly on this page. Objective: To develop a working knowledge of how the EV-400 (EV High-Voltage Safety trainer) uses the DC-to-DC Converter Discussion: On a vehicle there are many low voltage devices, such as lights, motors, sensors, etc. These items are con- nected to the low voltage battery, in the case of the EV-400, the battery is the 12VDC battery. It is located in the lower left side of the front panel. Think about how this would work in a real vehicle: Driving around in especially the dark would draw down the battery quickly. For this reason, most EV’s use a DC-to-DC converter that charges the battery and runs low voltage equipment. Required equipment: EV-400, power supply, High Voltage gloves, 110V outlet, Klein ET600 DMM and wiring diagrams. Procedure: 1. Plug in the EV-400 power supply into the left side of the trainer. 2. Plug in the power supply to the 110V outlet. 3. Perform the High Voltage glove test SA- 1. 4. With gloved hand, turn on the unit with the switch in the upper left corner. The green light should illuminate. There should be a red light near the key fob holder. 5. Place the key fob into the key fob holder. The orange ready light should be illuminated. 6. Ensure that all switches are closed labeled SW1, SW2, SW3, SW4, SW10, SW11 and SW12. 12VDC Battery switches should be up and AC, Heat switches to the left. P, R, D switch in P (park). 7. Measure the battery voltage. What does the meter read? VDC 8. Hold down the brake button and push the ignition button. 9. Once the ready light is on, read the voltage of the battery and record here: VDC 10. What did the battery voltage do? consulab.com info@consulab.com 33 95-EV-400 Section 3 — SA-11 11. Why did the voltage change? 12. What is the difference between an Inverter and a Converter? 13. Show your instructor your results and be prepared to explain how the DC / DC Converter works. Instructor grade : Instructor Signature : Comments : consulab.com info@consulab.com 34 95-EV-400 Section 3 — SA-12 SA-12 — Other HV Components Name : Group : Date : You should put your answers directly on this page. Objective: To develop a working knowledge of how additional High Voltage components are powered in the EV-400 (EV High-Voltage Safety trainer). Discussion: On a vehicle there are many High Voltage components that are powered by the HV system. On the EV-400 there are actually 4. So far we have looked at the drive motor through the Inverter and the DC-to-DC converter. In this lab you will look at the Cabin Heater and the A/C Compressor. These two components are more efficient if powered off of the High Voltage rather than the low voltage. A 1200W heater would draw 100 amps at 12 volts but only draws 3 amps at 400 volts. Wattage is a measure of the amount of work being done and it is a result of the Voltage times the Amperage. 12 V X 100 A = 1200 W and 400 V X 3 A = 1200 W. Both examples are using components that are DC. Note that some vehicles will use an A/C Compressor that runs off of Alternating Current (AC). Required equipment: EV-400, power supply, High Voltage gloves, 110V outlet, Klein ET600 DMM and wiring diagrams. Procedure: 1. Plug in the EV-400 power supply into the left side of the trainer. 2. Plug in the power supply to the 110V outlet. 3. Perform the High Voltage glove test SA- 1. 4. With gloved hand, turn on the unit with the switch in the upper left corner. The green light should illuminate. There should be a red light near the key fob holder. 5. Place the key fob into the key fob holder. The orange ready light should be illuminated. 6. Ensure that all switches are closed labeled SW1, SW2, SW3, SW4, SW10, SW11 and SW12. 12VDC Battery switches should be up and AC, Heat switches to the left. P, R, D switch in P (park). 7. Measure the HV at the Cabin Heater: V 8. Hold down the Brake button and push the Ignition button. 9. Once the ready light is on, read the voltage of the Cabin Heater and record here: VDC consulab.com info@consulab.com 35 95-EV-400 Section 3 — SA-12 10. This is the voltage available to the Cabin Heater. Turn on the heater at the control panel. Is there any indication that the heater is drawing current? Yes No 11. What is the voltage available to the A/C Compressor? VDC 12. Is there any indication that the A/C Compressor is drawing current? Yes No 13. Show your instructor your results and be prepared to explain how the HV components are wired. Instructor grade : Instructor Signature : Comments : consulab.com info@consulab.com 36 95-EV-400 Section 4 — Intro to HV Interlock Circuit Section 4 Intro to HV Interlock Circuit consulab.com info@consulab.com 37 95-EV-400 Section 4 — Intro to HV Interlock Circuit Intro to HV Interlock Circuit The High Voltage Interlock Circuit or HVIL is a circuit that runs through every major module that handles High Voltage. It is a circuit that must be working perfectly, or the High Voltage is not switched on. Consider how a high current relay functions. Low current flows through a coil of wire, that generates a magnetic field, that closes the contacts so high cur- rent can flow. This is the basics of the HVIL. It functions like a series circuit that runs through all HV modules. Any break or problem that interrupts the HVIL will have the EV Power Module shut down the High Voltage Contactors or not allow them to close. Look at the wiring diagram which is labeled EV-400 Educational Schematic – HVIL only and follow along. Beginning at the battery, where we know there are 2 - 200V batteries, notice that there is also a +5V feed. This is the beginning of the HVIL. Within the battery module these is a 120Ω resistance which is part of the power supply. The circuit continues out through the service disconnect where it goes up to the Contactors and a 330Ω resistor. Where does it go next and what type of circuit is this? The answer is the circuit continues into the High Voltage Distribution and is a series circuit. Think about a series circuit like that drawn below. We have three resistors wired in series. B+ is on the top and Ground at the bottom. The rectangles represent Volt meters and the round represent Amp meters. B+ V-1 V V-1 V V-3 V V-3 V V-2 V V-2 V R3 R3 R2 R2 R1 R1 A-1 A A-2 A A-2 A B+ V-1 V V-3 V V-2 V R3 R2 R1 A-1 A A-2 A RT = consulab.com info@consulab.com 38 95-EV-400 Section 4 — Intro to HV Interlock Circuit Answer the next questions. You should put your answers directly on this page. Name : Group : Date : 1. What type of circuit is this? A. Parallel B. Series C. Series/parallel 2. If the resistors are 4 Ω each, what is the total resistance of the circuit? A. 4 Ω B. 8 Ω C. 12 Ω D. 16Ω 3. Once you have verified answer #2, use the total resistance and a B+ or 12 V to calculate current. A. 1 A B. 4 A C. 12 A D. 3 A 4. What two conditions have to be present for there to be a voltage drop? A. Resistance and power flowing B. Current flowing through resistance C. Parallel circuit and ground D. Positive and negative 5. If the resistors are equal then... A. The voltage drop will be unequal B. It’s impossible to calculate C. The voltage drop will be equal Now let’s be specific. Fill in the multi-meters on the next page with 3 - 4Ω resistors. consulab.com info@consulab.com 39 95-EV-400 Section 4 — Intro to HV Interlock Circuit Fill in the multi-meters with 3 - 4Ω resistors. B+ V-1 V V-1 V V-3 V V-3 V V-2 V V-2 V R3 R3 R2 R2 R1 R1 A-1 A A-2 A A-2 A B+ V-1 V V-3 V V-2 V R3 R2 R1 A-1 A A-2 A RT = Show your instructor before going on. The importance of understanding voltage drops cannot be overstated. Many vehicles and the EV-400 use voltage drop measurements to identify a problem and open the HV circuit. Go back to the EV-400 Educational Schematic – HVIL. We left off in the Inverter. Notice C1 and C2 has the HVIL running through it. Now look at the full schematic that has both the HV and the HVIL and look at C1 and C2. This is very import- ant: Any connector that has High Voltage running through it will have the interlock loop also running through it. This is C1. In the center are two small prongs sticking out. This is the HVIL and it is essentially a jumper as seen on the HVIL wiring diagram. When C1 is disconnected, the jumper is opened electrically. The voltage drops ahead of C1 will go to 5 volts and the voltage drops after will go to 0 V. When the main control module sees 5 V at one connector and 0 V at the next, it knows that an open has occurred at C1 and it shuts down the High Voltage for safe- ty reasons. It is important to note that any orange connector on a vehicle will have High Voltage present and the HVIL. Remember that orange indicates a voltage over 60 V. Back to the diagram. consulab.com info@consulab.com 40 95-EV-400 Section 4 — Intro to HV Interlock Circuit 6. Where does the HVIL circuit go after C2? A. Contactors B. A/C Compressor C. Cabin Heater D. DC-to-DC converter Keep following the blue wires of the HVIL. Eventually you will wind up back at the battery module where the circuit will be grounded. So, we started at the Battery Module and looped through all modules and wound up back at the battery module. This is why the circuit is called an interlock loop. The service disconnect also has the HVIL running through it. If you remove it, it will look like this. Again there is a set of two pins or prongs in the middle of the picture. This is a jumper for the HVIL. Opening the Service Disconnect will open the HVIL and shut down the high voltage just like any other orange connector. The next series of student assignments will give you greater understanding of how the HVIL works. The service disconnect also has the HVIL running through it. If you remove it, it will look like this. Again there is a set of two pins or prongs in the middle of the picture. This is a jumper for the HVIL. Opening the Service Disconnect will open the HVIL and shut down the high voltage just like any other orange connector. The next series of student activities will give you greater understanding of how the HVIL works. Instructor grade : Instructor Signature : Comments : consulab.com info@consulab.com 41 95-EV-400 Section 4 — SA-13 SA-13 — Connections and the HVIL Name : Group : Date : You should put your answers directly on this page. Objective: To develop a working knowledge of how the HVIL is used as a control of the High Voltage circuit on the EV-400. Discussion: The HVIL controls the High Voltage. Whenever a High Voltage connector is used, it will carry the HVIL. Required equipment: EV-400, power supply, High Voltage gloves, 110V outlet, Klein ET600 DMM and wiring diagrams. Procedure: 1. Plug in the EV-400 power supply into the left side of the trainer. 2. Plug in the power supply to the 110V outlet. 3. Perform the High Voltage glove test SA- 1. 4. With gloved hand, turn on the unit with the switch in the upper left corner. The green light should illuminate. There should be a red light near the key fob holder. If not, place the key fob into the holder. 5. The orange ready light should be illuminated. 6. Ensure that all switches are closed labeled SW1, SW2, SW3, SW4, SW10, SW11 and SW12. 12VDC Battery switches should be up and AC, Heat switches to the left. P, R, D switch in P (park). 7. Hold down the Brake button and push the Ignition button. 8. Once the ready light is on, make sure the meter in the middle of the EV-400 reads approximately 400 VDC. 9. Remove the Service Disconnect. Note this takes 2 separate operations. Do not force any levers. Ask your instructor for help. A. Release the lock tab and pull the lever up. B. Press in the tab on the front of the service disconnect and remove it. 10. What is the voltage as shown on the meter? VDC 11. Identify the High Voltage connections and the HVIL connections. 12. Show your instructor your results and be prepared to explain how the HVIL runs through the service disconnect. 13. Re-install the service disconnect, clear the codes (push the ignition button) and restart the EV-400. Show your in- structor. Instructor grade : Instructor Signature : Comments : consulab.com info@consulab.com 42 95-EV-400 Section 4 — SA-14 SA-14 Connectors and the HVIL Name : Group : Date : You should put your answers directly on this page. Objective: To develop a working knowledge of how the HVIL is used as a control of the High Voltage circuit on the EV-400. Discussion: The HVIL controls the High Voltage. Whenever a High Voltage connector is used, it will carry the HVIL. Required equipment: EV-400, power supply, High Voltage gloves, 110V outlet, Klein ET600 DMM and wiring diagrams. Procedure: 1. Plug in the EV-400 power supply into the left side of the trainer. 2. Plug in the power supply to the 110V outlet. 3. Perform the High Voltage glove test SA- 1. 4. With gloved hand, turn on the unit with the switch in the upper left corner. The green light should illuminate. There should be a red light near the key fob holder. If not, place the key fob into the holder. 5. The orange ready light should be illuminated. 6. Ensure that all switches are closed labeled SW1, SW2, SW3, SW4, SW10, SW11 and SW12. 12VDC Battery switches should be up and AC, Heat switches to the left. P, R, D switch in P (park). 7. Hold down the brake button and push the ignition button. 8. Once the ready light is on, make sure the meter in the middle of the EV-400 reads approximately 400 VDC. 9. Remove the cable with C1 and C2. Note this takes 2 separate operations. Do not force any levers. Ask your instruc- tor for help. A. Release the lock tab toward the top of the connector and pull the lever up. B. Press in the tab on the tab toward the bottom of the connector and remove it completely. 10. What is the voltage as shown on the meter? VDC 11. Identify the High Voltage connections and the HVIL connections. 12. Show your instructor your results and be prepared to explain how the HVIL runs through the service disconnect. 13. Re-install the service disconnect, clear the codes (push the ignition button) and restart the EV-400. Show your instructor. Instructor grade : Instructor Signature : Comments : consulab.com info@consulab.com 43 95-EV-400 Section 4 — SA-15 SA-15 The HVIL’s Applied Voltage Name : Group : Date : You should put your answers directly on this page. Objective: To develop a working knowledge of how the HVIL is used as a control of the High Voltage circuit on the EV-400. Discussion: The HVIL controls the High Voltage. If the High Voltage is shut down the applied voltage can be read. This is a reference voltage that will be used by the control module to indicate an open circuit. Required equipment: EV-400, power supply, High Voltage gloves, 110V outlet, Klein ET600 DMM and wiring diagrams. Procedure: 1. Plug in the EV-400 power supply into the left side of the trainer. 2. Plug in the power supply to the 110V outlet. 3. Perform the High Voltage glove test SA- 1. 4. With gloved hand, turn on the unit with the switch in the upper left corner. The green light should illuminate. There should be a red light near the key fob holder. If not, place the key fob into the holder. 5. The orange ready light should be illuminated. 6. Ensure that all switches are closed labeled SW1, SW2, SW3, SW4, SW10, SW11 and SW12. 12VDC Battery switches should be up and AC, Heat switches to the left. P, R, D switch in P (park). 7. Hold down the brake button and push the ignition button. 8. Once the ready light is on, make sure the meter in the middle of the EV-400 reads approximately 400 VDC. 9. Open the high voltage switch SW1. 10. What is the voltage as shown on the meter? VDC. What does this indicate? 11. Using your HVIL wiring diagram identify the two IL sockets that are closest to the 5 VDC source. Place your meter across these sockets and record: VDC consulab.com info@consulab.com 44 95-EV-400 Section 4 — SA-15 12. Show your instructor your results and be prepared to identify where on the diagram you measured and the signifi- cance of your measurement. 13. Switch SW1 back on, clear the codes (push the ignition button) and restart the EV-400. Show your instructor. Instructor grade : Instructor Signature : Comments : consulab.com info@consulab.com 45 95-EV-400 Section 4 — SA-16 SA-16 — The HVIL’s Voltage Name : Group : Date : You should put your answers directly on this page. Objective: To develop a working knowledge of how the HVIL is used as a control of the High Voltage circuit on the EV-400. Discussion: The HVIL controls the High Voltage. If the High Voltage is shut down the applied voltage can be read. This is a reference voltage that will be used by the control module to indicate an open circuit. The control module can pinpoint the open circuit by seeing where the voltage is 5V and where it is 0V. Required equipment: EV-400, power supply, High Voltage gloves, 110V outlet, Klein ET600 DMM and wiring diagrams. Procedure: 1. Plug in the EV-400 power supply into the left side of the trainer. 2. Plug in the power supply to the 110V outlet. 3. Perform the High Voltage glove test SA- 1. 4. With gloved hand, turn on the unit with the switch in the upper left corner. The green light should illuminate. There should be a red light near the key fob holder. If not, place the key fob into the holder. 5. The orange ready light should be illuminated. 6. Ensure that all switches are closed labeled SW1, SW2, SW3, SW4, SW10, SW11 and SW12. 12VDC Battery switches should be up and AC, Heat switches to the left. P, R, D switch in P (park). 7. Hold down the brake button and push the ignition button. 8. Once the ready light is on, make sure the meter in the middle of the EV-400 reads approximately 400 VDC. 9. Open the high voltage switch SW1. 10. What is the voltage as shown on the meter? VDC. What does this indicate? 11. Place the negative (black) lead in the ground socket (bottom center of the EV-400) consulab.com info@consulab.com 46 95-EV-400 Section 4 — SA-16 12. With the meter set to VDC use the positive (red) meter lead to pinpoint the open part of the HVIL circuit. Note: only go into the positive IL sockets (white) that are in line with the HV (orange) + socket. 13. With SW1 open where do you have 5 V? 14. With SW1 open where do you have 0 V? 15. Show your instructor how you arrived at your conclusions. 16. Switch SW1 back on, clear the codes (push the ignition button) and restart the EV-400. Show your instructor. Instructor grade : Instructor Signature : Comments : consulab.com info@consulab.com 47 95-EV-400 Section 4 — SA-17 SA-17 — The HVIL’s Applied Voltage under Load Name : Group : Date : You should put your answers directly on this page. Objective: To develop a working knowledge of how the HVIL is used as a control of the High Voltage circuit on the EV-400. Discussion: The HVIL controls the High Voltage. If the High Voltage is shut down, the applied voltage can be read. This is a reference voltage that will be used by the control module to indicate an open circuit. The control module can pinpoint the open circuit by seeing where the voltage is 5V and where it is 0V. Once the IL circuit is closed and has current flowing the applied voltage will drop down (voltage drops). Required equipment: EV-400, power supply, High Voltage gloves, 110V outlet, Klein ET600 DMM and wiring diagrams. Procedure: 1. Plug in the EV-400 power supply into the left side of the trainer. 2. Plug in the power supply to the 110V outlet. 3. Perform the High Voltage glove test SA- 1. 4. With gloved hand, turn on the unit with the switch in the upper left corner. The green light should illuminate. There should be a red light near the key fob holder. If not, place the key fob into the holder. 5. The orange ready light should be illuminated. 6. Ensure that all switches are closed labeled SW1, SW2, SW3, SW4, SW10, SW11 and SW12. 12VDC Battery switches should be up and AC, Heat switches to the left. P, R, D switch in P (park). 7. Hold down the brake button and push the ignition button. 8. Once the ready light is on, make sure the meter in the middle of the EV-400 reads approximately 400 VDC. 9. Use your HVIL wiring diagram and note where you can measure the applied voltage to the circuit. Sockets: and 10. Measure the applied voltage at the points identified in step #9. What is the voltage as shown on your meter? VDC. What does this indicate? consulab.com info@consulab.com 48 95-EV-400 Section 4 — SA-17 11. Show your instructor where you measured the applied voltage and what the measurement was. 12. Show your instructor how you arrived at your conclusions. Instructor grade : Instructor Signature : Comments : consulab.com info@consulab.com 49 95-EV-400 Section 4 — SA-18 SA-18 — The HVIL’s Voltage Drops 1 Name : Group : Date : You should put your answers directly on this page. Objective: To develop a working knowledge of how the HVIL is used as a control of the High Voltage circuit on the EV-400. Discussion: The HVIL controls the High Voltage. If the High Voltage is shut down, the applied voltage can be read. This is a reference voltage that will be used by the control module to indicate an open circuit. The control module can pinpoint the open circuit by seeing where the voltage is 5 V and where it is 0 V. Once the IL circuit is closed and has current flow- ing the applied voltage will drop down (voltage drops). Each resistor in the series circuit will have a voltage drop. The sum of all the voltage drops will equal the applied under load voltage. Required equipment: EV-400, power supply, High Voltage gloves, 110V outlet, Klein ET600 DMM and wiring diagrams. Procedure: 1. Plug in the EV-400 power supply into the left side of the trainer. 2. Plug in the power supply to the 110V outlet. 3. Perform the High Voltage glove test SA- 1. 4. With gloved hand, turn on the unit with the switch in the upper left corner. The green light should illuminate. There should be a red light near the key fob holder. If not, place the key fob into the holder. 5. The orange ready light should be illuminated. 6. Ensure that all switches are closed labeled SW1, SW2, SW3, SW4, SW10, SW11 and SW12. 12VDC Battery switches should be up and AC, Heat switches to the left. P, R, D switch in P (park). 7. Hold down the brake button and push the ignition button. 8. Once the ready light is on, make sure the meter in the middle of the EV-400 reads approximately 400 VDC. 9. Use your HVIL wiring diagram and note where you can measure the applied voltage to the circuit. Sockets: and 10. Measure the applied voltage at the points identified in step #9. What is the voltage as shown on your meter? VDC. What does this indicate? consulab.com info@consulab.com 50 95-EV-400 Section 4 — SA-18 11. Measure the voltage between sockets IL1 and IL2. Record: VDC 12. Measure the HVIL voltage at each module. Are they the same or different? same different 13. What does each individual voltage indicate? 14. Add the voltages together (use your phone calculator). Total: VDC 15. Why did we add the voltages? 16. Why did the sum equal what it did? 17. Be prepared to discuss your results with your instructor. Instructor grade : Instructor Signature : Comments : consulab.com info@consulab.com 51 95-EV-400 Section 4 — SA-19 SA-19 — The HVIL’s Voltage Drops 2 Name : Group : Date : You should put your answers directly on this page. Objective: To develop a working knowledge of how the HVIL is used as a control of the High Voltage circuit on the EV- 400. Discussion: The HVIL controls the High Voltage. If the High Voltage is shut down, the applied voltage can be read. This is a reference voltage that will be used by the control module to indicate an open circuit. The control module can pinpoint the open circuit by seeing where the voltage is 5 V and where it is 0 V. Once the IL circuit is closed and has current flow- ing the applied voltage will drop down (voltage drops). Required equipment: EV-400, power supply, High Voltage gloves, 110V outlet, Klein ET600 DMM and wiring diagrams. Procedure: 1. Plug in the EV-400 power supply into the left side of the trainer. 2. Plug in the power supply to the 110V outlet. 3. Perform the High Voltage glove test SA- 1. 4. With gloved hand, turn on the unit with the switch in the upper left corner. The green light should illuminate. There should be a red light near the key fob holder. If not, place the key fob into the holder. 5. The orange ready light should be illuminated. 6. Ensure that all switches are closed labeled SW1, SW2, SW3, SW4, SW10, SW11 and SW12. 12VDC Battery switches should be up and AC, Heat switches to the left. P, R, D switch in P (park). 7. Hold down the brake button and push the ignition button. 8. Once the ready light is on, make sure the meter in the middle of the EV-400 reads approximately 400 VDC. 9. Use your HVIL wiring diagram. 10. Place the negative meter lead (black) into the ground socket 11. Place the positive lead (red) in the module applied voltage socket IL1. Record: VDC 12. Place the positive lead (red) in the module applied voltage socket IL5. Record: VDC 13. Place the positive lead (red) in the module applied voltage socket IL13. Record: VDC 14. Place the positive lead (red) in the module applied voltage socket IL7. Record: VDC consulab.com info@consulab.com 52 95-EV-400 Section 4 — SA-19 15. Place the positive lead (red) in the module applied voltage socket IL9. Record: VDC 16. Place the positive lead (red) in the module applied voltage socket IL11. Record: VDC 17. Place the positive lead (red) in the module applied voltage socket IL12. Record: VDC 18. The voltage is going , why? 19. What did the measurement in step #17 indicate? 20. Show your instructor your results and explain your conclusions. Instructor grade : Instructor Signature : Comments : consulab.com info@consulab.com 53 95-EV-400 Section 4 — SA-20 SA-20 — The HVIL’s Voltage Drops with an Open Circuit 1 Name : Group : Date : You should put your answers directly on this page. Objective: To develop a working knowledge of how the HVIL is used as a control of the High Voltage circuit on the EV-400. Discussion: The HVIL controls the High Voltage. If the High Voltage is shut down, the applied voltage can be read. This is a reference voltage that will be used by the control module to indicate an open circuit. The control module can pinpoint the open circuit by seeing where the voltage is 5 V and where it is 0 V. Once the IL circuit is closed and has current flow- ing the applied voltage will drop down (voltage drops). An open circuit “should” allow the voltage to go up to the unload- ed applied voltage. Required equipment: EV-400, power supply, High Voltage gloves, 110V outlet, Klein ET600 DMM and wiring diagrams. Procedure: 1. Plug in the EV-400 power supply into the left side of the trainer. 2. Plug in the power supply to the 110V outlet. 3. Perform the High Voltage glove test SA- 1. 4. With gloved hand, turn on the unit with the switch in the upper left corner. The green light should illuminate. There should be a red light near the key fob holder. If not, place the key fob into the holder. 5. The orange ready light should be illuminated. 6. Ensure that all switches are closed labeled SW1, SW2, SW3, SW4, SW10, SW11 and SW12. 12VDC Battery switches should be up and AC, Heat switches to the left. P, R, D switch in P (park). 7. Hold down the brake button and push the ignition button. 8. Once the ready light is on, make sure the meter in the middle of the EV-400 reads approximately 400 VDC. 9. Use your HVIL wiring diagram. 10. Place the negative meter lead (black) into the ground socket 11. Place the positive lead (red) in the module applied voltage socket IL7. Record: VDC consulab.com info@consulab.com 54 95-EV-400 Section 4 — SA-20 12. Turn switch SW2 down. What happened to the EV-400? 13. What does the voltmeter now read? VDC 14. Why does the voltmeter read as in step #13? Include in your answer voltage drops, how they occur and why: 15. Show your instructor your results and explain your conclusions. Instructor grade : Instructor Signature : Comments : consulab.com info@consulab.com 55 95-EV-400 Section 4 — SA-21 SA-21 — The HVIL’s Voltage Drops with an Open Circuit 2 Name : Group : Date : You should put your answers directly on this page. Objective: To develop a working knowledge of how the HVIL is used as a control of the High Voltage circuit on the EV-400. Discussion: The HVIL controls the High Voltage. If the High Voltage is shut down, the applied voltage can be read. This is a reference voltage that will be used by the control module to indicate an open circuit. The control module can pinpoint the open circuit by seeing where the voltage is 5 V and where it is 0 V. Once the IL circuit is closed and has current flow- ing the applied voltage will drop down (voltage drops). An open circuit “should” allow the voltage to go up to the unload- ed applied voltage. Required equipment: EV-400, power supply, High Voltage gloves, 110V outlet, Klein ET600 DMM and wiring diagrams. Procedure: 1. Plug in the EV-400 power supply into the left side of the trainer. 2. Plug in the power supply to the 110V outlet. 3. Perform the High Voltage glove test SA- 1. 4. With gloved hand, turn on the unit with the switch in the upper left corner. The green light should illuminate. There should be a red light near the key fob holder. If not, place the key fob into the holder. 5. The orange ready light should be illuminated. 6. Ensure that all switches are closed labeled SW1, SW2, SW3, SW4, SW10, SW11 and SW12. 12VDC Battery switches should be up and AC, Heat switches to the left. P, R, D switch in P (park). 7. Hold down the brake button and push the ignition button. 8. Once the ready light is on, make sure the meter in the middle of the EV-400 reads approximately 400 VDC. 9. Use your HVIL wiring diagram. 10. Place the negative meter lead (black) into the ground socket 11. Place the positive lead (red) in the module applied voltage socket IL7. Record: VDC consulab.com info@consulab.com 56 95-EV-400 Section 4 — SA-21 12. Turn switch SW4 down. What happened to the EV-400? 13. What does the voltmeter in IL7 now read? VDC 14. Move the + voltmeter lead to IL8. Record: VDC 15. Move the + voltmeter lead to IL9. Record: VDC 16. Move the + voltmeter lead to IL10. Record: VDC 17. Move the + voltmeter lead to IL11. Record: VDC 18. Move the + voltmeter lead to IL12. Record: VDC 19. What did this series of voltmeter readings indicate? 20. Are voltage drops occurring? Yes No 21. Why or why not? 22. Show your instructor your results and explain your conclusions. Instructor grade : Instructor Signature : Comments : consulab.com info@consulab.com 57 95-EV-400 Section 4 — SA-22 SA-22 — The HVIL’s Voltage Drops with Current Flowing Name : Group : Date : You should put your answers directly on this page. Objective: To develop a working knowledge of how the HVIL is used as a control of the High Voltage circuit on the EV-400. Discussion: The HVIL controls the High Voltage. If the High Voltage is shut down, the applied voltage can be read. This is a reference voltage that will be used by the control module to indicate an open circuit. The control module can pinpoint the open circuit by seeing where the voltage is 5 V and where it is 0 V. Once the IL circuit is closed and has current flow- ing the applied voltage will drop down (voltage drops). An open circuit “should” allow the voltage to go up to the unload- ed applied voltage. There are times that you may not be able to measure the actual voltage drop across a resistor. Get as close as you can and use your Wiring diagram. Required equipment: EV-400, power supply, High Voltage gloves, 110V outlet, Klein ET600 DMM and wiring diagrams. Procedure: 1. Plug in the EV-400 power supply into the left side of the trainer. 2. Plug in the power supply to the 110V outlet. 3. Perform the High Voltage glove test SA- 1. 4. With gloved hand, turn on the unit with the switch in the upper left corner. The green light should illuminate. There should be a red light near the key fob holder. If not, place the key fob into the holder. 5. The orange ready light should be illuminated. 6. Ensure that all switches are closed labeled SW1, SW2, SW3, SW4, SW10, SW11 and SW12. 12VDC Battery switches should be up and AC, Heat switches to the left. P, R, D switch in P (park). 7. Hold down the brake button and push the ignition button. 8. Once the ready light is on, make sure the meter in the middle of the EV-400 reads approximately 400 VDC. 9. Use your HVIL wiring diagram. 10. Place the negative meter lead (black) into the ground socket 11. Place the positive lead (red) in the module applied voltage socket IL12. Record: VDC 12. Use your wiring diagram and show your instructor where you are measuring consulab.com info@consulab.com 58 95-EV-400 Section 4 — SA-22 13. Why is this a different voltage than you have measured before? 14. Based on your wiring diagram, what are you measuring? 15. Show your instructor and be prepared to explain the significance of your readings. Instructor grade : Instructor Signature : Comments : consulab.com info@consulab.com 59 95-EV-400 Section 4 — Interlock Loop Quiz Interlock Loop Quiz You should put your answers directly on this page. Circle the correct letter. 1. The HVIL is a circuit that... A. Controls the High Voltage B. Turns on the contactors C. Changes DC into AC D. Is not present in the Service Disconnect 2. The voltage drop across each module of the HVIL... A. Is unequal B. Depends on position of the gear shift lever C. Is equal D. Is 12.6 volts 3. Technician A states that prior to using EV gloves, they should be tested and inspected. Technician B states that leather gloves should be placed over the rubber gloves to protect against tears or holes. Who is correct? A. Only Technician A B. Only Technician B C. Both Technician A and Technician B D. Neither Technician A nor Technician B 4. Two voltmeter readings are taken. One is 5 V and the other is 0 V. This indicates... A. The circuit is open between the two points B. The circuit is shorted between the two points C. The HV system is run at 400 V D. The HVIL power supply is faulted 5. Technician A states that the High Voltage system controls the Interlock Loop. Technician B states that the HVIL runs throughout the High Voltage circuit including any connectors. Who is correct? A. Only Technician A B. Only Technician B C. Both Technician A and Technician B D. Neither Technician A nor Technician B consulab.com info@consulab.com 60 95-EV-400 Section 4 — Interlock Loop Quiz 6. The Service Disconnect has... A. Only the HV circuit running through it B. Only the HVIL circuit running through it C. No circuit running through it D. Both the HV and the HVIL circuits running through it 7. What happens if there is a HVIL fault indicated? A. Both the HV and the HVIL will be down or open B. The 12-volt charge fault will also be on C. The vehicle can only be driven slowly D. None of the above 8. 5V in an HVIL socket indicates that... A. The fault is after the socket B. The fault is before the socket C. HVIL is up and running D. HVIL is shorted to ground 9. 0V in an HVIL socket indicates that the fault is... A. Not present B. After the socket C. Before the socket D. Cleared 10. The HVIL circuit goes down and the fault light goes on when the vehicle is put in gear. This indicates that the most likely place for the fault is... A. DC-to-DC Converter B. A/C Compressor C. Inverter D. Drive Motor Instructor grade : Instructor Signature : Comments : consulab.com info@consulab.com 61 95-EV-400 Section 5 — Introduction to Fault Diagnosis and Isolation Testing Section 5 Introduction to Fault Diagnosis and Isolation Testing consulab.com info@consulab.com 62 95-EV-400 Section 5 — Introduction to Fault Diagnosis and Isolation Testing Introduction to Fault Diagnosis and Isolation Testing Up to this point we have done a series of assignments designed to familiarize you with how an electric vehicle functions. We have looked at the High Voltage and the High Voltage Interlock circuits with an eye as to how they work and how the system uses voltage drops to determine if and where a problem exists. It is now time to look at how the vehicle displays or transmits the problems to the technician. This is done in usually one of two ways. Either a technician plugs a scanner into the DLC and reads data and DTC’s or the information shows up on the vehicle dash screen. The EV-400 will generate lights to indicate faults. At this point you should have enough experi- ence to realize how you will use your multimeter to diagnose HV or HVIL faults. This last section of the student manual will go into a bit more of the basics of diagnostics and will introduce you to test- ing for isolation. Isolation of the HV voltage is a way of saying that the High Voltage is insulated from the vehicle chassis. Only the vehicle battery and low voltage equipment use the chassis ground. As you have seen, the High Voltage has its own paths, components, cables and connections. All parts of the HV circuit must be isolated from chassis ground. It will take a specialized meter like the Klein ET600 or equivalent to do isolation testing. A normal multimeter will test resis- tance usually at less than 12 volts. Testing at 12 V for a component running at 400 V is not really testing the HV system. Isolation testing is a type of stress test and a very important skill for you to have. consulab.com info@consulab.com 63 95-EV-400 Section 5 — Function of Loss of Isolation (LOI) Function of Loss of Isolation (LOI) Understanding Loss of Isolation (LOI) in Electric Vehicles: Definition, Testing, and Safety Measures Before we try to determine loss of isolation in SA-27 (Student Assignment #27), it is important to look at what isolation is. Keep in mind that an EV will have very distinct circuits. It will have a series of 12 VDC circuits, an HVIL (High Voltage Integrated Loop), and a High Voltage circuit. For safety and function the high voltage must never come into contact with the other circuits. If, for instance, the High Voltage were to come into contact with the chassis ground, all metal on the vehicle would be at 400 volts. Anyone touching the chassis would experience 400 Volts and possibly die from electro- cution. The separation between the circuits is done by an extreme amount of resistance and is called isolation. The 400 Volts is isolated from the chassis ground and other circuits. You will see in SA-27 how this isolation is tested using a special meter which will stress test the system at up to 1000 VDC. Pay attention to the safety measures written here for your own safety. Testing Testing the insulation of high-voltage cables on electric vehicles is a critical aspect of ensuring electrical safety and reliable performance. Various methods are employed to assess the integrity of the insulation system. The “Dielectric Withstand Voltage”, or Hipot Test, involves subjecting the cables to voltages higher than normal operational levels to evaluate the insulation’s breakdown strength. Insulation Resistance Tests measure the resistance between conductors and between conductors and ground, providing insight into the insulation’s quality and detecting potential issues like moisture ingress. Cable Capacitance Measurement assesses changes in capacitance, which can indicate insulation deg- radation. To follow safety standards and manufacturer guidelines, along with testing by qualified personnel, is essential for accurate and reliable results in assessing high-voltage cable insulation on electric vehicles. Safety Measures Performing an insulation test on electric vehicles, is a critical step in ensuring the safety and reliability of the high-volt- age system. Please note that any procedures should be conducted by qualified personnel, and it’s important to follow specific guidelines and recommendations: • Always follow proper safety procedures, including the use of personal protective equipment and adherence to elec- trical safety standards. • Remember that working with high-voltage systems poses inherent risks, and testing should only be performed by individuals with the necessary training and qualifications. • If you are not familiar with high-voltage systems or testing procedures, it is recommended to seek assistance from qualified professionals or contact Tesla for guidance. • Perform the isolation/insulation test when diagnosis requires verification that a circuit or component is properly isolated, or a cable has sufficient insulation. consulab.com info@consulab.com 64 95-EV-400 Section 5 — Function of Loss of Isolation (LOI) • 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. • 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. • Warning: Make sure that the insulation meter and leads are capable of handling at least 1000V DC. • 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. • Warning: If corrective eyewear is necessary to safely perform any procedure, make sure that the eyewear is secure- ly restrained to the head and cannot fall off. • Warning: Always wear High Voltage (HV) gloves and safety glasses when handling any high voltage component, in- cluding test equipment. Before each use, test gloves using an authorized glove tester and verify that the testing date on the gloves has not expired. • Warning: All repair and operating instructions should be reviewed and understood before working on Tesla vehicles, associated components, or associated repair equipment. • Warning: Assume that high voltage is always present when working on a Tesla vehicle, associated high voltage com- ponents, 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. • 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. • 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. • Warning: If any test equipment fails to operate as expected, do not attempt to diagnose or repair the vehicle. Fol- low the appropriate lock out – tag out procedure for the equipment, notify your manager. • Warning: When using test equipment, make sure that all cables are connected before turning equipment on or oth- erwise initiating use. • Warning: Only technicians who have been trained in High Voltage Awareness and have completed all required certi- fication 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 always worn 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. • 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. 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. • Install the probes to the tester. • Set the tester to measure isolation/insulation MOhms (MΩ) scale. • Set the tester to the test voltage appropriate for the component being measured. consulab.com info@consulab.com 65 95-EV-400 Section 5 — SA-23 SA-23 — Fault Diagnosis 1 Name : Group : Date : You should put your answers directly on this page. Objective: To develop a working knowledge of how faults are recorded and diagnosed on the EV-400. Discussion: Fault diagnosis on an EV is an integral part of the technician’s job. It is usually done in one of two methods. If the vehicle has a DLC, a scanner is connected and reads the Diagnostic Trouble Codes. If the vehicle does not have a DLC, it is common practice to display on the dash screen the fault codes or at least turn on a light. The EV-400 displays lights and since it does not have a DLC. A scanner cannot be connected to the EV-400. Point of information: Currently most EV’s that are made by a company that also produces gas powered vehicles, will have a DLC. If the company does not produce gas powered vehicles (Tesla, Rivian, etc), it will typically not have a DLC and will display diagnostics on the dash display. Required equipment: EV-400, power supply, High Voltage gloves, 110V outlet, Klein ET600 DMM and wiring diagrams. Procedure: 1. Plug in the EV-400 power supply into the left side of the trainer. 2. Plug in the power supply to the 110V outlet. 3. Perform the High Voltage glove test SA- 1. 4. With gloved hand, turn on the unit with the switch in the upper left corner. The green light should illuminate. There should be a red light near the key fob holder. If not, place the key fob into the holder. 5. The orange ready light should be illuminated. 6. Ensure that all switches are closed labeled SW1, SW2, SW3, SW4, SW10, SW11 and SW12. 12VDC Battery switches should be up and AC, Heat switches to the left. P, R, D switch in P (park). 7. Hold down the Brake button and push the Ignition button. 8. Once the ready light is on, make sure the meter in the middle of the EV-400 reads approximately 400 VDC. 9. Use your HVIL wiring diagram. 10. Choose any HV switch. Switch it off 11. Did the action turn on any lights in the Fault Indicator section of the trainer? Yes No consulab.com info@consulab.com 66 95-EV-400 Section 5 — SA-23 12. Which light(s) are on? 13. Why did the light(s) go on? What else happened to the trainer? 14. Place the switch back to the normal position. Did the lights go off? Yes No 15. Try to restart the unit by placing your finger on the Brake switch and pushing the Ignition button. Did the EV-400 re- start? Yes No 16. Clearing codes is a function of the Ignition button. If it is pushed alone (with no other button), the codes should clear turning the lights off. 17. Re-start the EV-400. Record the voltage from the meter here: VDC 18. Show your instructor and be prepared to explain the significance of your readings. Instructor grade : Instructor Signature : Comments : consulab.com info@consulab.com 67 95-EV-400 Section 5 — SA-24 SA-24 — Fault Diagnosis 2 Name : Group : Date : You should put your answers directly on this page. Objective: To develop a working knowledge of how faults are recorded and diagnosed on the EV-400. Discussion: Fault diagnosis on an EV is an integral part of the technician’s job. It is usually done in one of two methods. If the vehicle has a DLC, a scanner is connected and reads the Diagnostic Trouble Codes. If the vehicle does not have a DLC, it is common practice to display on the dash screen the fault codes or at least turn on a light. The EV-400 displays lights and since it does not have a DLC. A scanner cannot be connected to the EV-400. Point of information: Currently most EV’s that are made by a company that also produces gas powered vehicles, will have a DLC. If the company does not produce gas powered vehicles (Tesla, Rivian, etc), it will typically not have a DLC and will display diagnostics on the dash display. Any difficulties with either the HV circuits or the HVIL will turn on both lights since the circuits are closely related. Required equipment: EV-400, power supply, High Voltage gloves, 110V outlet, Klein ET600 DMM and wiring diagrams. Procedure: 1. Plug in the EV-400 power supply into the left side of the trainer. 2. Plug in the power supply to the 110V outlet. 3. Perform the High Voltage glove test SA- 1. 4. With gloved hand, turn on the unit with the switch in the upper left corner. The green light should illuminate. There should be a red light near the key fob holder. If not, place the key fob into the holder. 5. The orange ready light should be illuminated. 6. Ensure that all switches are closed labeled SW1, SW2, SW3, SW4, SW10, SW11 and SW12. 12VDC Battery switches should be up and AC, Heat switches to the left. P, R, D switch in P (park). 7. Hold down the Brake button and push the Ignition button. 8. Once the ready light is on, make sure the meter in the middle of the EV-400 reads approximately 400 VDC. 9. Use your combined HV and HVIL wiring diagram . consulab.com info@consulab.com 68 95-EV-400 Section 5 — SA-24 10. Open the First Responder Loop. What happened? 11. Did the action turn on any lights in the Fault Indicator section of the trainer? Yes No 12. Which light(s) are on? 13. Why did the light(s) go on? What else happened to the trainer? 14. Re-connect the First Responder’s Loop. Did the lights go off? Yes No 15. Try to restart the unit by placing your finger on the brake switch and pushing the ignition button. Did the EV-400 re- start? Yes No 16. Clearing codes is a function of the Ignition button. If it is pushed alone (with no other button), the codes should clear turning the lights off. 17. Re-start the EV-400. Record the voltage from the meter here: VDC 18. Show your instructor and be prepared to explain the significance of your readings. Instructor grade : Instructor Signature : Comments : consulab.com info@consulab.com 69 95-EV-400 Section 5 — SA-25 SA-25 — Fault Diagnosis 3 Name : Group : Date : You should put your answers directly on this page. Objective: To develop a working knowledge of how faults are recorded and diagnosed on the EV-400. Discussion: Fault diagnosis on an EV is an integral part of the technician’s job. It is usually done in one of two methods. If the vehicle has a DLC, a scanner is connected and reads the Diagnostic Trouble Codes. If the vehicle does not have a DLC, it is common practice to display on the dash screen the fault codes or at least turn on a light. The EV-400 displays lights and since it does not have a DLC. A scanner cannot be connected to the EV-400. Point of information: Currently most EV’s that are made by a company that also produces gas powered vehicles, will have a DLC. If the company does not produce gas powered vehicles (Tesla, Rivian, etc), it will typically not have a DLC and will display diagnostics on the dash display. Any difficulties with either the HV circuits or the HVIL will turn on both lights since the circuits are closely related. Removing the Service Disconnect will effectively shut down the entire vehicle or the EV-400. Required equipment: EV-400, power supply, High Voltage gloves, 110V outlet, Klein ET600 DMM and wiring diagrams. Procedure: 1. Plug in the EV-400 power supply into the left side of the trainer. 2. Plug in the power supply to the 110V outlet. 3. Perform the High Voltage glove test SA-1. 4. With gloved hand, turn on the unit with the switch in the upper left corner. The green light should illuminate. There should be a red light near the key fob holder. If not, place the key fob into the holder. 5. The orange ready light should be illuminated. 6. Ensure that all switches are closed labeled SW1, SW2, SW3, SW4, SW10, SW11 and SW12. 12VDC Battery switches should be up and AC, Heat switches to the left. P, R, D switch in P (park). 7. Hold down the Brake button and push the Ignition button. 8. Once the ready light is on, make sure the meter in the middle of the EV-400 reads approximately 400 VDC. 9. Use your combined HV and HVIL wiring diagram. 10. Measure battery voltage at sockets HV3 and HV4: VDC consulab.com info@consulab.com 70 95-EV-400 Section 5 — SA-25 11. Using your HV gloves, remove the Service Disconnect. What happened? 12. Did the action turn on any lights in the Fault Indicator section of the trainer? Yes No 13. Which light(s) are on? 14. Why did the light(s) go on? What else happened to the trainer? 15. Measure the voltage at HV3 and HV4: VDC 16. Try to restart the unit by placing your finger on the brake switch and pushing the ignition button. Did the EV-400 re- start? Yes No 17. Clearing codes is a function of the Ignition button. If it is pushed alone (with no other button), the codes should clear turning the lights off. 18. Re-start the EV-400. Record the voltage from the meter here: VDC 19. Show your instructor and be prepared to explain the significance of your readings. Instructor grade : Instructor Signature : Comments : consulab.com info@consulab.com 71 95-EV-400 Section 5 — SA-26 SA-26 — Fault Diagnosis 4 Name : Group : Date : You should put your answers directly on this page. Objective: To develop a working knowledge of how faults are recorded and diagnosed on the EV-400. Discussion: Fault diagnosis on an EV is an integral part of the technician’s job. It is usually done in one of two methods. If the vehicle has a DLC, a scanner is connected and reads the Diagnostic Trouble Codes. If the vehicle does not have a DLC, it is common practice to display on the dash screen the fault codes or at least turn on a light. The EV-400 displays lights and since it does not have a DLC. A scanner cannot be connected to the EV-400. Point of information: Currently most EV’s that are made by a company that also produces gas powered vehicles, will have a DLC. If the company does not produce gas powered vehicles (Tesla, Rivian, etc), it will typically not have a DLC and will display diagnostics on the dash display. Any difficulties with either the HV circuits or the HVIL will turn on both lights since the circuits are closely related. Removing the Service Disconnect will effectively shut down the entire vehicle or the EV-400. The interaction of the DC-to-DC converter is different from other faults. You should be able to see the difference in the activity. Required equipment: EV-400, power supply, High Voltage gloves, 110V outlet, Klein ET600 DMM and wiring diagrams. Procedure: 1. Plug in the EV-400 power supply into the left side of the trainer. 2. Plug in the power supply to the 110V outlet. 3. Perform the High Voltage glove test SA- 1. 4. With gloved hand, turn on the unit with the switch in the upper left corner. The green light should illuminate. There should be a red light near the key fob holder. If not, place the key fob into the holder. 5. The orange ready light should be illuminated. 6. Ensure that all switches are closed labeled SW1, SW2, SW3, SW4, SW10, SW11 and SW12. 12VDC Battery switches should be up and AC, Heat switches to the left. P, R, D switch in P (park). 7. Hold down the Brake button and push the Ignition button. 8. Once the ready light is on, make sure the meter in the middle of the EV-400 reads approximately 400 VDC. 9. Use your combined HV and HVIL wiring diagram. consulab.com info@consulab.com 72 95-EV-400 Section 5 — SA-26 10. Measure battery voltage at sockets + and – at the battery: VDC 11. Move SW5 or SW6 down. What happened? 12. Did the action turn on any lights in the Fault Indicator section of the trainer? Yes No 13. Which light(s) are on? 14. Why did the light(s) go on? What else happened to the trainer? 15. Measure the voltage at the + and – of the battery: VDC 16. Switch the battery switch back up. Did the light go off? Yes No 17. What is different about this fault when compared to the other faults? 18. Show your instructor and be prepared to explain the significance of your readings. Instructor grade : Instructor Signature : Comments : consulab.com info@consulab.com 73 95-EV-400 Section 5 — SA-27 SA-27 — Isolation Testing Name : Group : Date : You should put your answers directly on this page. Objective: To develop a working knowledge of how the HV insulation is tested for its ability to be isolated from the vehi- cle chassis ground. Discussion: It is important that the high voltage in a vehicle does not have a path to the chassis. This is especially im- portant since the driver and/or technician comes in contact with the chasis while driving or repairing any system. This is called Isolation testing. It is testing with a specialized meter measuring the effective resistance between a high voltage component or cable and the chassis ground. There should be an extreme amount of resistance present insuring that there will be no leakage of high voltage to the chassis circuits of the vehicle. We will test the inverter, but any high volt- age component or cable/connector can be isolation tested. Required equipment: EV-400, power supply, High Voltage gloves, 110V outlet, Klein ET600 DMM and wiring diagrams. Procedure: 1. Plug in the EV-400 power supply into the left side of the trainer. Do not turn it on. 2. Isolate the inverter by pulling the Service Disconnect and C1 or C2. 3. Make sure unit is off and key fob is out of its holder. 4. Note: the Klein ET600 will generate high voltage. You must wear HV gloves during the test. 5. Determine what the test voltage should be. Use manufactures specifications. For the EV-400 use 500 V. Turn the meter knob to the 500V position. 6. Place the positive lead in the VΩ position. Place the other end of the positive meter lead into the COM port. This shorts the two inputs together to test the meter leads. 7. Press and hold the TEST button down until the meter displays a reading. Record here: Ω Note: Your read- ing should be zero or very close to zero since you are measuring the resistance of the positive lead. 8. Repeat the test with the negative lead. Record here: Ω 9. Place the negative lead of the meter in the ground socket located along the bottom of the EV-400. 10. Place the positive lead in the HV 13 socket of the inverter. consulab.com info@consulab.com 74 95-EV-400 Section 5 — SA-27 11. Press and hold the test button until the meter reading stabilizes. Record your reading here: Ω. Note: Your reading should be in the Megaohm range 12. Repeat steps 10 and 11 with the positive meter lead in the HV 14 socket. Record your reading here: Ω. 13. Determine if this is an acceptable reading based on the following. A perfect reading is OL or infinity. However, to be isolated, the reading must be greater than 100 ohms per volt DC at the testing voltage. Test voltage of 500 VDC X 100 Ω = 50,000 Ω. 14. Did the Inverter pass or fail the test? 15. Demonstrate to your instructor how to do an isolation test. Be prepared to discuss your results. Instructor grade : Instructor Signature : Comments : consulab.com info@consulab.com 75 95-EV-400 Section 6 — Optional Assignments Section 6 Optional Assignments consulab.com info@consulab.com 76 95-EV-400 Section 6 — SA-28 SA-28 — Live-Dead-Live Testing Name : Group : Date : You should put your answers directly on this page. Objective: To develop a working knowledge of how the process of Live-Dead-Live testing is done. When dealing with lethal voltages it is important that the meter accurately measures especially dead or no voltage circuits. To be able to trust the meter reading a technician will follow the Live-Dead-Live procedure. Required equipment: EV-400, power supply, High Voltage gloves, safety glasses, 110V outlet, Klein ET600 DMM and wiring diagrams. Procedure: 1. Plug in the EV-400 power supply into the left side of the trainer. 2. Plug in the power supply to the 110V outlet. 3. Perform the High Voltage glove test SA- 1. 4. With gloved hand, turn on the unit with the switch in the upper left corner. The green light should illuminate. 5. Place the key fob into the key fob holder. The orange ready light should be illuminated. 6. Insure that all switches are closed labeled SW1, SW2, SW3, SW4, SW10, SW11 and SW12. 12 VDC Battery switches should be up and AC, Heat switches to the left. P, R, D switch in P (park). 7. Start the EV-400 by holding down the brake button as you push the ignition button. 8. What does the green meter face show in the center of the EV-400? VDC 9. Open switch SW3. Note: This should put the EV-400 into a fault mode and turn on the Interlock and the High Volt- age fault lights. 10. What voltage does the green display show? VDC 11. Are the two fault lights illuminated? Yes No 12. If the EV-400 is in a fault mode, we will begin the process of determining if meter readings are accurate. 13. Place the meter into DC Volts position and measure the battery voltage at the + and – terminals of the 12 V battery. Record the meter reading: VDC Note: This is the Live portion of the test procedure. 95-EV-400 Section 6 — SA-28 consulab.com info@consulab.com 77 14. Move the meter leads to the HV1 and HV2 positions at the contactors. Record the meter reading: VDC Note: This is the Dead portion of the test procedure. 15. Place the meter into DC Volts position and measure the battery voltage at the + and – terminals of the 12 V battery. Record the meter reading: VDC Note: This is the 2nd and final Live portion of the test procedure. 16. Why do we do this procedure? 17. Show your instructor your results and be prepared to explain how and why Live-Dead-Live testing is done. Instructor grade : Instructor Signature : Comments : consulab.com info@consulab.com 78 95-EV-400 Section 6 — SA-29 SA-29 — Section or Component Identification Name : Group : Date : You should put your answers directly on this page. Objective: To develop a working knowledge of how the various sections of the EV-400 function together or in sequence. Required equipment: EV-400. Procedure: Open up the EV-400 case and examine each section. Note: Each section has dotted lines around it. Be pre- pared to indicate what most of the sections do, and how they are connected. EV-400_053287-93 Component Identification consulab.com info@consulab.com 8 Section 1 — Master Switch and Fault Box 1. Power ON Lamp 2. Master ON/OFF Switch 3. Standby Lamp 4. Inserted Fault LED Indicators 5. Fault Insertion Buttons 6. Fault Type LED Indicators 7. Fault Lockable Key Switch 13 2 4 7 5 6 EV-400 Component Identification 1 2 3 4 5 6 7 95-EV-400 Section 6 — SA-29 consulab.com info@consulab.com 79 SECTION 1 1. What this section does in the EV-400? 2. How this section is connected? SECTION 2 3. What this section does in the EV-400? 4. How this section is connected? SECTION 3 5. What this section does in the EV-400? 6. How this section is connected? SECTION 4 7. What this section does in the EV-400? 8. How this section is connected? 95-EV-400 Section 6 — SA-29 consulab.com info@consulab.com 80 SECTION 5 9. What this section does in the EV-400? 10. How this section is connected? SECTION 6 11. What this section does in the EV-400? 12. How this section is connected? SECTION 7 13. What this section does in the EV-400? 14. How this section is connected? Instructor grade : Instructor Signature : Comments : consulab.com info@consulab.com 81 95-EV-400 Educational Schematics Educational Schematics consulab.com info@consulab.com 82 95-EV-400 Educational Schematics C A BI N H EA T A /C C O M PR ES SO R D C /D C C O N V ER TE R H V BA TT ER Y C O N TA C TO RS IN V ER TE R/ M O TO R H IG H V O LT A G E D IS TR IB U TI O N SW 1 SW 4 SW 12 SW 3 SW 11 SW 2 SW 10 C 2 C 1 P R D FI RS T RE SP O N D ER ’S L O O P 40 0 V D C /1 2V D C C O N V ER TE R SE RV IC E D IS C O N N EC T C O N TR O L PA N EL IG N A C H EA T BR A K E G A S 33 0 Ω IL 1 IL 2 IL 13 IL 14 1. 8 kΩ IL 4 IL 3 12 0 Ω +5 V 33 0 Ω IL 5 IL 6 33 0 Ω IL 11 IL 12 33 0 Ω IL 10 IL 9 33 0 Ω IL 7 D C 1 IL 8 D C 2 + - SW 5 SW 6 12 V D C BA TT ER Y 33 0 Ω RE V 8 EV -4 0 0 E d uc at io na l S ch em at ic - H V IL o nl y © C on su La b Ed uc at ec h In c. , 2 02 4. A ll ri gh ts r es er ve d consulab.com info@consulab.com 83 95-EV-400 Educational Schematics C A BI N H EA T A /C C O M PR ES SO R D C /D C C O N V ER TE R H V BA TT ER Y C O N TA C TO RS IN V ER TE R/ M O TO R H IG H V O LT A G E D IS TR IB U TI O N SW 1 SW 4 SW 12 SW 3 SW 11 SW 2 SW 10 C 2 C 1 P R D FI RS T RE SP O N D ER ’S L O O P 40 0 V D C /1 2V D C C O N V ER TE R SE RV IC E D IS C O N N EC T C O N TR O L PA N EL IG N A C H EA T BR A K E G A S H V 13 H V 14 SM R3 SM R2 SM R1 H V 1 H V 2 H V 4 H V 15 H V 16 H V 3 H V 11 H V 12 H V 9 H V 10 H V 5 H V 6 H V 7 H V 8 U V W N IN V ER TE R 20 0V Ba tt er y 20 0V Ba tt er y RE V 8 EV -4 0 0 E d uc at io na l S ch em at ic - H V o nl y © C on su La b Ed uc at ec h In c. , 2 02 4. A ll ri gh ts r es er ve d consulab.com info@consulab.com 84 95-EV-400 Educational Schematics C A BI N H EA T A /C C O M PR ES SO R D C /D C C O N V ER TE R H V BA TT ER Y C O N TA C TO RS IN V ER TE R/ M O TO R H IG H V O LT A G E D IS TR IB U TI O N SW 1 SW 4 SW 12 SW 3 SW 11 SW 2 SW 10 C 2 C 1 P R D SE RV IC E D IS C O N N EC T C O N TR O L PA N EL FI RS T RE SP O N D ER ’S L O O P 40 0 V D C /1 2V D C C O N V ER TE R IG N A C H EA T BR A K E G A S H V 13 H V 14 SM R3 SM R2 SM R1 H V 1 H V 2 H V 4 H V 15 H V 16 H V 3 H V 11 H V 12 H V 9 H V 10 H V 5 H V 6 H V 7 H V 8 U V W N IN V ER TE R 20 0V Ba tt er y 20 0V Ba tt er y 33 0 Ω IL 1 IL 2 IL 13 IL 14 1. 8 kΩ IL 4 IL 3 12 0 Ω +5 V 33 0 Ω IL 5 IL 6 33 0 Ω IL 11 IL 12 33 0 Ω IL 10 IL 9 33 0 Ω IL 7 D C 1 IL 8 D C 2 + - SW 5 SW 6 12 V D C BA TT ER Y 33 0 Ω RE V 8 EV -4 0 0 E d uc at io na l S ch em at ic - H V & H V IL © C on su La b Ed uc at ec h In c. , 2 02 4. A ll ri gh ts r es er ve d consulab.com info@consulab.com 85 95-EV-400 Notes Notes 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2025. All rights reserved. Section 1 The Basics of an EV The Basics of an EV Safety Section 2 Safety when working on an EV Safety when working on an EV SA-1 — Checking your PPE SA-2 — Meter Use SA-3 — Introduction to the EV-400 SA-4 — Measuring Various Voltages on the EV-400 SA-5 — Safety Devices Safety when Working on an EV — Exam Section 3 Intro to High Voltage Intro to High Voltage High Voltage — Quiz SA-6 — Introduction to the EV-400 Batteries SA-7 — Introduction to the EV-400 Contactors SA-8 — High Voltage Distribution SA-9 — The HV Inverter SA-10 — Measuring 3-Phase AC SA-11 — DC-to- DC Converter SA-12 — Other HV Components Section 4 Intro to HV Interlock Circuit Intro to HV Interlock Circuit SA-13 — Connections and the HVIL SA-14 Connectors and the HVIL SA-15 The HVIL’s Applied Voltage SA-16 — The HVIL’s Voltage SA-17 — The HVIL’s Applied Voltage under Load SA-18 — The HVIL’s Voltage Drops 1 SA-19 — The HVIL’s Voltage Drops 2 SA-20 — The HVIL’s Voltage Drops with an Open Circuit 1 SA-21 — The HVIL’s Voltage Drops with an Open Circuit 2 SA-22 — The HVIL’s Voltage Drops with Current Flowing Interlock Loop Quiz Section 5 Introduction to Fault Diagnosis and Isolation Testing Introduction to Fault Diagnosis and Isolation Testing Function of Loss of Isolation (LOI) Understanding Loss of Isolation (LOI) in Electric Vehicles: Definition, Testing, and Safety Measures SA-23 — Fault Diagnosis 1 SA-24 — Fault Diagnosis 2 SA-25 — Fault Diagnosis 3 SA-26 — Fault Diagnosis 4 SA-27 — Isolation Testing Educational Schematics
