Insulation fault

Example

Use in Lemonergy

Relate protection to faults, detection and response.

This is a reference concept. No executable Lemonergy block has been verified for this term.

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Diagnostic trouble code

A coded fault a controller stores when a check fails — a cell overvoltage, a sensor out of range, an isolation fault — with a status and often a snapshot of conditions when it occurred. Reading and interpreting DTCs is the first step of any battery root-cause analysis.

Equipotential bonding

Connecting every exposed metal part — pack enclosure, motor frame, charger case — firmly to the chassis so that none can sit at a different voltage after an insulation fault. UN R100 requires under 0.1 Ω between exposed conductive parts and the chassis, measured with at least 0.2 A; during conductive charging the chassis is also tied to protective earth.

Insulation resistance

The resistance between the high-voltage circuit and the vehicle chassis, which must stay above about 100 Ω per volt of pack voltage so a person touching the chassis is safe. An insulation monitoring device measures it continuously.

Insulation resistance test

Applying a high DC or AC voltage between the high-voltage circuit and the chassis or housing to verify that insulation holds, with the leakage current below a limit. It is done on every pack at end of line and after abuse tests in R100.

Voltage class

The line between circuits that need high-voltage protection and those that do not. UN R100 calls a circuit high voltage above 60 V DC or 30 V AC rms, up to 1500 V DC or 1000 V AC; ISO 6469-3 calls the same band voltage class B and anything lower class A. A 48 V system stays below the line.

References & further reading

Further reading on this topic

These sources provide broader context; they are not presented as citations for every statement in this entry.

1. ISO 26262-1:2018 — Road vehicles — Functional safety — Part 1: Vocabulary

   International Organization for Standardization · 2018

   Topic background · Scope and terminology of automotive electrical/electronic functional safety. The catalogue is not the full standard.