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Vehicle Electrical Isolation Procedure: Notes

Last modified: 22/06/2023 14:38:44

G15087230Courtesy of TESLA, INC.
NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.
WARNING: This procedure is a DRAFT, although it has been validated. Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near high voltage systems and components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.
WARNING: This procedure verifies that high voltage power is no longer available to high voltage components (A/C compressor, inverters, etc.). Perform this procedure before servicing high voltage components.
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 securely restrained to the head and cannot fall off.
WARNING: Always wear High Voltage (HV) gloves and safety glasses when handling any high voltage component, including test equipment. Before each use, test gloves using an authorized glove tester and verify that the testing date on the gloves has not expired.
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 present at all times when working on a Tesla vehicle, associated high voltage components, or associated high voltage test equipment until proven otherwise. Be aware that energy states can change during testing, so err on the side of caution.
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: Use a high voltage digital multimeter to check for the presence of high voltage on both sides of the connector every time a high voltage connector is disconnected.
WARNING: Make sure that the insulation meter and leads are capable of handling at least 500V DC.
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. Follow 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 otherwise initiating use.
WARNING: High voltage is present on battery recovery chargers whenever the HV LEDs are lit. However, indicators and LEDs can fail. Do not assume that if an LED is not lit no high voltage is present. Assume high voltage is present at all times until proven otherwise by use of a multimeter.
WARNING: Only technicians who have been trained in High Voltage Awareness  and have completed all required certification courses (if applicable) are permitted to perform this procedure. Proper personal protective equipment (PPE)  and insulating HV gloves  with a minimum rating of class 0  (1000V) must be worn at all times a high voltage cable, busbar, or fitting is handled. Refer to Tech Note TN-15-92-003, "High Voltage Awareness Care Points" for additional glove and safety information.
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