Hioki EV HV SYSTEM ADV TEST KIT – Advanced EV HV System Test Kit (FT3700-20, DT4261, RM3548, Z5041, 9465-11, IR4059, 5 X Z5020, C0213)

• Combines several components and accessories used in testing of electric and hybrid vehicle systems
• RM3548 portable DC resistance meter and IR4059 insulation resistance tester
• FT3700-20 handheld infrared thermometer and DT4261 digital multimeter
• Z5041 protector case for RM3548
• Adds magnetic straps and pin-type test leads to standard EV HV system test kit

The items below combine to form an ideal kit suitable for EV maintenance testing. Included in the test kit are meters for measuring high and low resistance values as well as voltage (among the other features common to a multimeter). A thermometer provides the ability to determine if battery packs are exhibiting symptoms that warrant further exploration. Two separate cases provide protection and storage for the equipment.

This advanced kit adds five Z5020 magnetic straps for securing the multimeter, DC resistance tester, and IR tester as well as pin-type test leads for the RM3548 milliohmmeter.

The RM3548 is a portable 4-terminal DC miliohmmeter. The resistance measurement conducted by this meter with a measurement current ranging from 500 nA to 1 A satisfies the ECE-R-100 measurement current requirement. The meter offers stability and precision in a wide resistance measurement range of 3 milliohms (with 0.1 microohm resolution) to 3 megaohms (with 100 ohm resolution).

This equipotential bonding test is performed after the installation or replacement of high-voltage (HV) components. In this test, the technician needs to verify that all chassis, shields, and other components are electrically connected without any issues. The resistance of the ground connection at the area where the chassis of the vehicle and the HV components are connected is measured. If the resistance value is high or substantially unstable (high variability), the HV component’s connection may have been improperly installed.

Insulation resistance testing is an essential part of maintenance and inspection to prevent electric shocks from battery electric vehicles (BEVs). This is especially true since the test checks for proper insulation that protects from the dangerously high voltages of EVs. Furthermore, this test will continue to grow in importance as the EV market keeps increasing the voltages of EVs year-on-year. In this test, we verify that there are no flaws in the insulation between the high-voltage (HV) system and the ground. Important measurement locations include inverter, motor, chassis, HV cable, and HV batteries.

The IR4059 insulation resistance tester is a great choice for measuring BEV insulation. For the HV range (500 V or 1000 V), the IR4059 has a safety feature that requires the technician to unlock in addition to choosing the voltage to prevent erroneous operation of applying high-voltage to low-voltage equipment. The included L9788-10 lead with remote switch and LED indicator allows you to start and stop the measurement at your fingertips and provides pass/fail judgments while the measurement is in progress.

Measure the surface temperature of the HV battery with a non-contact thermometer. In this inspection, check for variations in temperature as well as areas of high temperature. These may indicate issues that need further investigation.

The FT3700-20 is an infrared thermometer with a two-point laser marker that measures the average surface temperature inside a circle formed by the two points. It features a pistol design with an easy-to-see display. A full menu of basic measuring functions is available. Infrared temperature guns identify the surface temperature of an object by measuring the energy level of the infrared rays emitted from the object without physically contacting it.

This measurement is conducted to prevent electric shock and to make sure that the vehicle is shut down. Safety from electrocution is ensured by measuring the voltage on surfaces that are likely to be touched when unplugging the HV connector. In this test, voltage should be measured between specific points and the chassis ground of the vehicle. It should show up as zero volts (0 V).

The DT4261’s terminal shutters make it physically impossible to insert the wrong test lead when measuring. The LoZ (low input impedance) mode eliminates the effects of ghost voltages induced by the stray capacitance of the measurement target and the high input impedance of the multimeter. Installing the Wireless Adapter Z3210 (sold separately) to the DT4261 allows Bluetooth connections. By connecting the instrument to the mobile app GENNECT Cross, you can digitize and manage your measurement data.

The Z5041 protector case fits around the RM3548 and provides a sure grip for the user, while the C0213 carrying case is large enough to accommodate all instruments.

The 9465-11 pin-type test leads feature a 153-inch length for the black lead, and the magnetic straps are used to hang the multimeter, DC resistance tester, and IR tester.