Perform protective ground conductor and insulation resistance measurement

AR47.70-S-1030-03E

Perform protective ground conductor and insulation resistance measurement

 Danger

Risk of death when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC)

Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines.

AS00.00-Z-0035-01A

Topical note

General information on vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system as well as personal protective equipment

AH00.00-Z-0300-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

Notes on battery

AH54.10-P-0001-01A



000 588 00 19 00 Insulation measuring unit

WS54.00-P-0046B

Engine

780.701 in model 447

Perform protective earth conductor and insulation resistance measurement on the vehicle socket (1) for feed-in of the high-voltage battery charger (5)

Shown on ECE (type 2) vehicle socket (1) (alternating current)

L1

Phase L1

1

Vehicle socket

4

Electrical connector

L2

Phase L2

2

Socket flap

5

High-voltage battery charger

N

Neutral conductor

3

Plug

6

Ground point

PE

Protective earth conductor

1

Open socket flap (2).

2

Detach plug (3).

3

Check vehicle socket (1), electrical wiring harness and electrical connector (4) for damage and wear.

 Visual inspection.

If there is a problem,



Replace vehicle socket (1) with electrical wiring harness.

4

Calibrate insulation resistance meter as per manufacturer's specifications.

5

Adjust insulation resistance meter for resistance test.

6

Perform resistance measurement with insulation resistance meter between the protective earth conductor (PE) and the earth point (6) of the high-voltage battery charger (5).

If the measured value falls within the specified range of < 1 (+0.9) Ω,



Proceed with operation step 10.

If the measured value does not fall within the specified range of < 1 (+0.9) Ω,



Proceed with step 7.

7

Release and disconnect electrical connector (4).

8

Perform resistance measurement with insulation resistance meter between the protective earth conductor (PE) in the vehicle socket (1) and the protective earth conductor (PE) in the electrical connector (4).

If the measured value falls within the specified range of < 1 (+0.9) Ω,



Check/repair earth point (6) or replace high-voltage battery charger (5).

If the measured value does not fall within the specified range of < 1 (+0.9) Ω,



Replace vehicle socket (1) with electrical wiring harness.

9

Connect and lock electrical connector(4).

10

Adjust insulation resistance meter for insulation resistance test and 500 V.

11

With a test voltage of 500 V, perform insulation resistance measurement with an insulation resistance meter between phase L1 (L1) and the protective earth conductor (PE).

If the measured value falls within the specified range of > 1 MΩ,



continue with operation step 15.

If the measured value does not fall within the specified range of > 1 MΩ,



Proceed with step 12.

12

Release and disconnect electrical connector (4).

13

With a test voltage of 500 V, repeat insulation resistance measurement with an insulation resistance meter between phase L1 (L1) and the protective earth conductor (PE).

If the measured value falls within the specified range of > 1 MΩ,



Replace high-voltage battery charger (5).

If the measured value does not fall within the specified range of > 1 MΩ,



Replace vehicle socket (1) with electrical wiring harness.

14

Connect and lock electrical connector(4).

15

With a test voltage of 500 V, perform insulation resistance measurement with an insulation resistance meter between phase L2 (L2) and the protective earth conductor (PE).

If the measured value falls within the specified range of > 1 MΩ,



continue with operation step 19.

If the measured value does not fall within the specified range of > 1 MΩ,



continue with operation step 16.

16

Release and disconnect electrical connector (4).

17

With a test voltage of 500 V, repeat insulation resistance measurement with an insulation resistance meter between phase L2 (L2) and the protective earth conductor (PE).

If the measured value falls within the specified range of > 1 MΩ,



Replace high-voltage battery charger (5).

If the measured value does not fall within the specified range of > 1 MΩ,



Replace vehicle socket (1) with electrical wiring harness.

18

Connect and lock electrical connector(4).

19

With a test voltage of 500 V, perform insulation resistance measurement with an insulation resistance meter between the neutral conductor (N) and the protective earth conductor (PE).

If the measured value falls within the specified range of > 1 MΩ,



continue with operation step 23.

If the measured value does not fall within the specified range of > 1 MΩ,



continue with operation step 20.

20

Release and disconnect electrical connector (4).

21

With a test voltage of 500 V, repeat insulation resistance measurement with an insulation resistance meter between the neutral conductor (N) and the protective earth conductor (PE).

If the measured value falls within the specified range of > 1 MΩ,



Replace high-voltage battery charger (5).

If the measured value does not fall within the specified range of > 1 MΩ,



Replace vehicle socket (1) with electrical wiring harness.

22

Connect and lock electrical connector(4).

Perform protective earth conductor and insulation resistance measurement on charging cable (7)

Shown on charging cable (7) with full assignment

L1

Phase L1

N

Neutral conductor

7.1

Connector

L2

Phase L2

PE

Protective earth conductor

7.2

Jack

L3

Phase L3

7

Charging cable

23

Remove plug from bushing (7.2).

24

Check charging cable (7), connector (7.1) and bushing (7.2) for damage and wear.

 Visual inspection.

If there is a problem,



Replace charging cable (7).

25

Calibrate insulation resistance meter as per manufacturer's specifications.

26

Adjust insulation resistance meter for resistance test.

27

Perform resistance measurement between connector (7.1) and bushing (7.2) with the insulation resistance meter of the protective earth conductor (PE).

If the measured value does not fall within the specified range of < 1 (+0.9) Ω,



Replace charging cable (7).

28

Adjust insulation resistance meter for insulation resistance test and 500 V.

29

With a test voltage of 500 V, perform insulation resistance measurement between phase L1 (L1) and the protective earth conductor (PE) with the insulation resistance meter on the connector (7.1) or the bushing (7.2).

If the measured value does not fall within the specified range of > 1 MΩ,



Replace charging cable (7).

30

With a test voltage of 500 V, perform insulation resistance measurement between phase L2 (L2) and the protective earth conductor (PE) with the insulation resistance meter on the connector (7.1) or the bushing (7.2).

If the measured value does not fall within the specified range of > 1 MΩ,



Replace charging cable (7).

31

With a test voltage of 500 V, perform insulation resistance measurement between phase L3 (L3) and the protective earth conductor (PE) with the insulation resistance meter on the connector (7.1) or the bushing (7.2).

If the measured value does not fall within the specified range of > 1 MΩ,



Replace charging cable (7).

32

With a test voltage of 500 V, perform insulation resistance measurement between the neutral conductor (N) and the protective earth conductor (PE) with the insulation resistance meter on the connector (7.1) or the bushing (7.2).

If the measured value does not fall within the specified range of > 1 MΩ,



Replace charging cable (7).