SFN-20231219C_ Perform IRM test

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TICO Document #: SFN-20231219C (formerly TES 272)

Description of Procedure: Procedure to safely perform an insulation resistance measurement (IRM) test when a Traction Voltage component or cable has been replaced/installed.

Units Affected: TICO/Volvo Penta Electric Vehicles

Tools Required:

Planned Labor: 20 minutes

This procedure should only be conducted on a fully decommissioned unit. Refer to TES-271 to ensure that all decommissioning steps were followed.

NOTE: The following procedures should only be conducted by personnel certified as β€œTechnician responsible for work activity” as defined in Volvo Group Safety STD 871-003. Always use the PPE that is described in these instructions.

Instructions:

  1. The vehicle must be parked in a weather-protected area when traction voltage components are opened and exposed. Also, the live working zone should be properly isolated and marked as safe, per Volvo Group Safety STD 871-0003 (Figure #3).

  2. Remove the 3/8” hardware from the gearbox cover grating, the Left-Hand Side cabinet grating, and the top panel of the Left-Hand Side cabinet. Set aside hardware (Figure #4).

  3. Remove and set aside the gratings and panel, exposing the TV junction box and batteries (Figure #5).

  1. Remove the inner and outer lid of the TV junction box (Figures #6 & #7), exposing the positive (+) and negative (-) busbars. Set aside lids.

  1. Set the insulation tester to 1000 V.

  1. Perform an insulation test across:

    β€’ Positive (+) busbar and TV junction box case ground (Figure #9).

    β€’ Negative (-) busbar and TV junction box case ground (Figure #10).

    IMPORTANT: If low insulation resistance is found ( < 1.5 MΞ©, +/- 0.5 MΞ© ), stop this procedure and contact technical service.

    • If insulation resistance is found to be within the acceptable range, continue with this procedure.

  1. Re-install the inner and outer lid of the TV junction box (Figures #11 & #12). Torque the M6 hardware for the outer lid to 17.5 ft-lb in the sequence shown in Figure #11.

  1. Re-install the gearbox cover grating, the top panel of the Left-Hand Side cabinet, and the Left-Hand Side cabinet grating (Figure #13).

  1. Return vehicle to service.