EMS 2.1.1

Testing the Battery NEXT Testing the battery prior to loading or transport is necessary in scenarios
where there is exposed wiring, loose high-voltage (HV) components,
or a significant risk of thermal runaway. Testing the Battery Responding to Electric Shock Incidents If a worker suffers an electric shock and remains in contact with the voltage source,
use an HV rescue hook to safely pull the worker away. Under no circumstances
should you attempt to pull a worker away without the correct safety equipment
(refer to required PPE protocols). NEXT Testing the Battery Using a CAT III, 1000V Multimeter or Voltage Detector When testing an HV battery in battery electric vehicles (BEVs), plug-in hybrid
electric vehicles (PHEVs), or hybrid vehicles, a CAT III-rated multimeter with
matching CAT III leads must be used. Using incorrect equipment can result in
electric shock, causing severe injury or death. NEXT Testing the Battery • Inspect the CAT III multimeter and leads to confirm they are rated for 1000V
and free from damage or defects. • Recognize that if the multimeter is malfunctioning, it may display zero voltage even when
up to 700 volts are present, posing a significant safety hazard. This initial test ensures
accurate readings during the vehicle assessment. Multimeter Testing Protocol: • Follow the Live-Dead-Live Testing Principle (see video, next topic) • Test the multimeter on a known power source to verify it is functioning correctly. • Test the multimeter against a known power source, such as the vehicle's 12-volt battery,
to verify it is functioning correctly. NEXT • Measure the HV battery at a designated test point, checking for zero voltage. • Re-test the multimeter on the original power source to confirm it continues
to operate accurately. This process prevents erroneous readings, which could result in significant hazards
if the equipment falsely displays zero voltage when active HV power is present. Testing the Battery A short circuit on a high-voltage battery can lead to severe equipment failure
and personal injury. To safeguard operators and reduce risks, always: Precautionary Practices NEXT • Measure directly at high-voltage connections, as HV circuits are isolated
from the chassis ground. • Adhere strictly to the manufacturer’s testing recommendations. • Conduct tests in a well-lit, dry, and debris-free environment. • Never leave the HV system unattended during testing, as the battery
remains charged even when isolated. Testing the Battery Battery testing and multimeter use must only be performed by trained personnel.
Attempting these procedures without proper instruction can lead to hazardous situations. Training Requirements NEXT Testing the Battery • Ensure all personnel responsible for battery testing are fully trained
and acknowledge these protocols. Action Items to Consider: • Confirm that all testing equipment complies with CAT III, 1000V
safety standards and undergoes routine functionality checks.
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