With more and more manufacturers bringing out EV models, and more EV only manufacturers coming to market, the number of EV on the UK road network is increasing. In 2023 EVs, including hybrids, accounted for 17.8% of all new registrations, and in the first half of 2024 that number has risen to 38.4% of all new registrations. There are now around 1.2 million fully electric battery cars on Britain's roads.

With the increasing numbers, more garages and workshops are going to be looking to expand into the market, as customers look for maintenance and diagnostic support away from main dealers. This page will highlight some of the equipment needed and how Warwick Test Supplies can help with providing equipment and tooling for the EV world.

Workshop Equipment - Safety and PPE

With Electric Vehicles, the main hazards are associated with the high voltage levels in the batteries. Voltages up to 700V DC can be present, so maintaining excellent electrical safety protocols is essential.

Firstly a barrier system should be used to fence off EVs while they are being worked on. This can help to prevent any accidental interference. A simple plastic barrier and chain link system can be used but it must be visible. At WTS we stock a red/white post with warning signs. 

Next we stock rescue hooks, which are essential in the event of electrical shock, allowing people to safely remove the victim from the electrical source without endangering themselves. Available in 2 lengths, 1.5m and 2m, they are manufactured by Sibille Fameca, and are despatched with an electrical safety notice to display with the hook.

Also in stock we supply Insulating Gloves, Helmets, Boric acid solutions and various warning boards to display around your workshop, to keep you as safe as possible. Read our blog on Insulated Gloves

Follow the link below to see the full range of safety equipment we stock:

 https://warwickts.com/4840/EV-Workshop-Safety-and-PPE

Workshop Equipment - Tools and Diagnostics

As part of getting ready to work on EVs and hybrids, a supply of insulated tools is required. As a distributer for Sibille Fameca we stock a whole range of insulated tools, whether you are looking for a spanner or two, a screwdriver set or a full socket set. Tools are rated to 1000V and conform to EN/60900 / IEC60900.

Also in stock are insulated bags. These are used to place the conductors in when removed from the car, they have a Velcro seal at the top, and are used to prevent conductors shorting on other parts of the car when disconnected. They come in 2 sizes, 130mm x 210mm and 225mm x 305mm. The bags can be purchased individually, or as a workshop kit, consisting of 2 of each size.

Now we come onto a selection of test and diagnostic equipment. As distributors of Fluke, Amprobe and PJP we have tester kits that can be used to test and diagnose issues with EV chargers and charging infrastructure. Test leads are also available that fit onto individual pins within the charge port of EVs to allow connection to your multimeter for testing of the charging port and circuitry associated with it. A guide to test leads can be found here Insulation Testing Leads - Type 2 Connections of Electric Vehicles

 Within our workshop we are also able to create bespoke solutions for EV diagnostics. As well as our range of breakout leads for auto connectors, we have designed a 3 phase breakout box as shown below. These allow a technician to test and connect the 3 phase wiring without damaging the cable and braiding. This allows ease of testing of the stator and field windings of the drive motors, and current testing by using a current clamp or inductive tester. Currently we have variations that fit the Mitsubishi plug in hybrid range, a variation that fits the Prius range and also a version that has ports to allow the use of magnetic test probes to safely measure voltage when power is on.

These designs are manufactured completely in house, and can be customised for different connectors if required. 

Our full range is linked below, if you can't see what you need, or require some guidance contact us for some assistance.

https://warwickts.com/1852/Vehicle-Diagnostic-Insulated-Tools

A new product for the electrical installation testing of electrical boards, consumer units and other electrical switches that utilise screw terminals.  This new AdaBV-140 screw terminal flexible adapter is rated at CAT III 1000V that enables additional safety for a technician conducting these tests, even when live voltage is present.  It meets the safety requirements for testing of 3-phase electrical boards.

The AdaBV140 consists of a 2.50mm² insulated flexible solid copper conductor and shrouded 4mm Banana socket with a finger guard to protect against inadvertent touching of a conductor under test.  The 4mm socket enables connection to common electrical test and measurement equipment such as multimeters, power analysers, insulation testers and oscilloscopes. 

The flexible nature of the adapter enables the connection of test equipment even in the most cramped and tight spaces.

Once connected to the screw terminal the protective finger guard enables technicians to connect and disconnect measuring devices even when live voltage is present.

Available in the following colours:

• Black
• Red
• Yellow
• Green
• Blue
• White

During servicing, maintenance and repair of Electric and Hybrid Vehicles (EV/PHEV) there is a requirement to conduct insulation tests of cables, connectors, motors, generators and battery packs.  One of the difficulties is to create a safe and reliable connection at the point of test.   Use of handheld probes or crocodile clips is clumsy, unreliable and potentially unsafe.

To assist a technician in this insulation resistance testing process Electro-PJP have designed and created new socket connector test leads to make the testing process easier, safer and hands free. 

 How to Conduct and Insulation Resistance Test of a Type 2 inlet connector

• Using EVF6 Insulation Test leads connect one lead to the centre Protective Earth and another to either a Phase or Neutral pin of the Type 2 inlet connector. 
• Connect the test leads to an Insulation tester.
• Conduct the insulation test using the appropriate test voltage.
• Repeat for the other Phase pins.

Note that using the EVF6 test leads allows you to conduct the test hands free. 

How to Conduct and Insulation Resistance Test of a Type 2/CCS Combo inlet connector

• Using EVF6 Insulation Test leads conduct the insulation resistance tests of the Type 2 inlet of the Type 2/CCS combo connector as described above.
• Once the Type 2 element is complete, connect an EVF6 Insulation Test Lead to the centre Protective Earth of the Type 2 inlet and then an EVF8 Insulation Test Lead to either the DC+ or DC- pin of the CCS inlet. 
• Connect the test leads to an Insulation tester.
• Conduct the insulation test using the appropriate test voltage.
• Repeat for the other CCS pin.

Note that using the EVF6/EV8 test leads allow you to conduct the test hands free. 

How to Conduct and Insulation Resistance Test of a CCS inlet connector

• Conduct the insulation resistance tests of the Type 2/CCS combo connector as described above.
• Once complete, connect EVF8 Insulation Test Leads to the DC+ and DC- pins of the CCS inlet. 
• Connect the test leads to an Insulation tester.
• Conduct the insulation test using the appropriate test voltage.

Note that using the EV8 test leads allow you to conduct the test hands free. 

Additional testing

Using the EVF6 and EVF8 Insulation Test Leads a technician can also conduct continuity resistance testing to check the electrical bonding between the centre Protective Earth pin of the Type 2 connector or combo CCS inlet and any metal frame or accessible conductive parts of the vehicle.

To do so requires connection to the centre Protective Earth pin using an EVF6 Insulation Test Lead and additional test probe which is then touched against conductive parts of the vehicle.

EVF6-2410-IEC-150 Insulation Test Lead	EVF8-2410-IEC-150 Insulation Test Lead

During servicing, maintenance and repair of Electric and Hybrid Vehicles (EV/PHEV) there is a requirement to conduct insulation tests of cables, connectors, motors, generators and battery packs.  One of the difficulties is to create a safe and reliable connection at the point of test.   Use of handheld probes or crocodile clips is clumsy, unreliable and potentially unsafe.

To assist a technician in this testing process Electro-PJP have designed and created a new socket connector to make available a specific EV/PHEV Insulation Test lead. 

This socket connector is designed to safely and reliably connect to the 6mm pins on a Type 2 connector and any other high voltage connector that also use a 6mm pin.  Note that vehicles fitted with CCS connectors also have 6mm pins on the Type 2 element of the connector.

Rated at 1000V CAT III/ 600V CAT IV 12A IEC61010, you can be sure in knowledge that the test lead meets the safety standards required to keep risks to as low as reasonably practical.

The Insulation Test Lead is terminated with a 4mm right angled shrouded banana plug so that it can be plugged straight into the sockets of an Insulation Tester, regardless of the tester brand such as Fluke, Megger, etc..  A useful guide on Insulation Testers for Automotive diagnostics is worth a read.

Also available is an Insulation Test Lead designed for connection to Delphi/ Aptiv RCS800 and RCS 890 connectors often found on early Renault and Nissan EVs.

Available for order from 01 September 2022 until 31st December 2022, Fluke have put some special pricing deals together on their popular 1660 series installation testers. Choosing either the 1662, 1663 or 1664FC Installation Testers there are bundles available including access to the Fluke TruTest software, or by purchasing one of the Installation Testers then you can claim a free Voltage and Continuity tester.

Fluke 1660 Series Installation Testers

 The 1660 series of installation testers are multi-function testers that take a wide ranging series of readings to assist the user when testing installations. They are the only installation testers available that help prevent damage to connected appliances, by conducting an 'Insulation Pre-Test' and providing a visual warning if connected appliances are detected. Another helpful feature is the switchable auto start for RCD and loop tests, saving time. The Testers also allow users to send wirelessly via a smart device directly from the field, via the Fluke Connect system.

 Measurements available are:

• Measurement function
• Voltage & frequency
• Wiring polarity checker, detects broken N wires
• Insulation resistance
• Continuity & resistance
• Measure motor windings with continuity test
• Loop & line resistance
• Prospective earth fault current (PEFC/IK)
• Prospective short-circuit current (PSC/IK)
• RCD switching time
• RCD tripping level (ramp test)
• Measures trip time & current for RCD type A & AC in one test
• RCD variable current
• Automatic RCD test sequence
• Phase sequence indicator

Fluke TruTest Software

These testers can now be bought, on offer, bundled together with the TruTest Advanced Software. 

The Fluke TruTest software is designed to eliminate the hassle associated with traditional electrical system data management and reporting. Whether you are testing appliances in an office, verifying repairs in  a workshop or performing annual inspections, the software provides proper data management solutions which allows the production of easy-to-understand reports for clients and users.  Compatible with a growing list of Fluke and Beha-Amprobe test and measurement devices TruTest Software allows you to quickly import measurement results directly from your test instruments, manage files transferred from instruments, or manually enter the data as required. 

With a streamlined user interface and intuitive workflow, measurement data can easily be formatted into printable test certificates and reports complete with your company logo and electronic signature.

• Easily manage measurement data
• Quickly create test certificates and reports
• Free updates for 5 years after installation
• Easy data collection and database transfers
• Enables manual data entry 
• Intuitive user interface
• Fast and simple operations
  
  

Buy an Installation Tester -- Get a selected Voltage tester FREE.

 If the TruTest software is not of use, then Fluke are also offering an offer where the purchase of a qualifying Installation Tester will also come with a free Voltage and Continuity Tester. 

The options are:

• Buy a 1662 Installation Tester - get a free T90 Voltage Tester
• Buy a 1663 Installation Tester - get a free T110 Voltage Tester
• Buy a 1664FC Installation Tester - get a free T6-1000 Voltage Tester.

Any of these offers can now be ordered via the special offers page of the website here: Fluke Autumn Special Offers

A new test kit containing the Amprobe 2100 voltage tester, Probe test probe extenders and a holster to house it in. Voltage and continuity tester with phase sequence indication, resistance measurement and NCV. Extremely robust tester with doubly insulated wires.  No unintentional triggering of RCD/FI circuit breakers and can be used with fast single-handed testing of power sockets with 19 mm contact clearance, without the probe coming away from the unit.  Measurement points can also be lit with the integral white LED. Extenders allow you to take voltage measurements in tight spaces and hard to access parts. The extenders ensure reliable contact without compromising safety, and are especially designed to allow measurement at fuse switch disconnectors and at busbars inside switchboards.

The kit contains:

• 2100-GAMMA voltage tester.
• 2100-ACC Probe test probe extenders.
• CC-2100 holster.

Safety requirements for electrical switchboards are getting more rigorous and electrical parts are increasingly protected by covers to ensure they won’t be accidently touched. As electrical contact points become more covered, it is becoming harder to ensure reliable contact for testing without having to remove protective covers.

Test probes on average voltage testers are generally too short for these enhanced isolators, making it difficult to measure voltage.

The kit is perfect for anyone requiring a reliable two pole voltage tester for voltage and continuity checks in hard to reach places. 

Amprobe 2100-GAMMA:

• CAT IV 600V/CAT III 100V
• LCD readout of voltages up to 1000V AC/1200V DC
• Voltage and Continuity readings
• Digital LCD 12…1000 V AC/ 1200 V DC
• Measures resistance up to 1999 Ohm
• Optical and acoustic continuity and voltage test
• Low resistance continuity measurement <10...50 Ohm
• Patented phase rotation indicator, no 3rd hand required
• Single-pole phase test
• Polarity
• Non-contact voltage (NCV/EF) detection.
• Switchable load (load tester) of 300 W at 1000 VAC / 420 W at 1200 VDC via two push buttons, triggering a RCD/FI up to 30 mA
• IP 64, water and dust-resistant
• Integrated probe-tip protection for reducing the danger of injuries.

The probe extenders:

• CAT IV 1000V/ CAT III 1500V
• Are especially designed to be used at fuse switch disconnectors and busbars inside switchboards with isolators and isolation switches.
• Fit on all Amprobe 2100 testers as well as the Fluke T90/110/130/150

Integrated Circuits (IC) Test Clips are useful across may electrical based applications. Common applications range from; production testing, prototyping, field service and quality control inspections. The invaluable Test Clip creates an easy access to IC Leads for probes and mitigates the risk of shorting and damaging fragile PC board chips.

IC Test Clips are available in various formats and contact types. Discover answers to common queries and questions relating to IC Test Clips.

1 - What is an IC Test Clip?

2 - What are the types of IC Test Clips?

3 - What are the IC Test Clip Contact Types? 

4 - IC Test Clip Summary

1 - What is an IC Test Clip?

2 - What are the Types of IC Test Clips?

IC Test Clips are available in various packages and pin configurations for different electrical applications. Below is a list of industry popular IC Test Clips

Dual In-Line (DIL) or Dual In-Line Package (DIP)

IC Test Clips are manufactured from a robust plastic and have two rows of interconnnects along two opposite sides of the package. The DIP is a common through-hole IC package with up to 84 pins and the most common lead pitch is 2.54mm (1.78 and 1.27mm are less common).

Small Outline Integrated Circuit (SOIC) or Small Outline Package (SOP)

The small outline IC package is the most common package type for low pin count ICs. It is lead frame-based plastic package with leads on two sides of the body and pin counts ranging from 8 to 84. The original lead pitch is 1.27mm, but shrink small outline packages (SSOP) with smaller pitches of 0.8, 0.635, and 0.5mm are available as well. Fully encapsulated SOP with a total package height of less than 1mm are often termed think small outline packages (TSOP).

Plastic Leadless Chip Carrier (PLCC)

A PLCC has a rectangular plastic housing. It is a reduced cost evolution of the ceramic leadless chip carrier (CLCC). The PLCC utilises a ‘J-Lead’ with pin spacing pitch of 1.27mm. The pin strip forming the lead is wrapped around and under the edge of the package, resembling the J in cross-section. Lead counts range from 20 to 84. The PLCC is preferred over DIP style chip carriers when lead counts exceed 40 pins due to the PLCC’s more efficient use of board surface area.

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3 - What are the IC Test Clip Contact Types?

IC Test Clips feature various contact types for specific applications and connection requirements. Each contact type has been designed for a specific device to ensure; high normal force, positive electrical connection and long-term performance.

 

Knife edge	Sharpened 'knife' like contacts designed to breakthrough oxides and conformal coatings
Duckbill	Flattened contacts for maximum interface surface area on the IC pins.
SOIC	Occupies an area about 30-50% less than an equivalent DIP

 

 

 

 

 

 

 

4. Summary

Integrated Circuits (IC) Test Clips are important pieces of electrical test equipment to enable; production testing, prototyping, field service and quality control inspections. IC Test Clip Package types, counts (number of pins) and contact styles differ greatly. Matching suitable IC Test Clips for your application can be difficult. If you have any doubt please contact us for IC Test Clip product advice.

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Insulated Safety Footwear Guide for EV Diagnostic Technicians

Insulated Safety Footwear is used to protect a user from electric shock when working on live high voltage electrical systems. Insulated safety footwear is commonly available in either shoe or boot style and categorised into one of 6 classes, dependant on the voltage levels that may be encountered and their electrical requirements.

This guide will focus on Class 0 Insulated Safety Footwear that is the minimum standard to be used for EV/PHEV vehicle diagnostics and repair. Discover answers to common queries and questions related to insulated safety footwear.

1 - What is Insulated Safety Footwear?

2 - When should Electrically insulating Footwear be worn?

3 - Insulated Safety Footwear Ratings and Safety Guide

4 - How to look after your insulated Safety Footwear

5 - Testing your insulated Safety Footwear

6 - Buyers Tips - EV Diagnostic Technicians Footwear

1 - What is Insulated Safety Footwear?

2 - When Should Electrically Insulating Footwear be worn?

Insulating footwear is used by many individuals across many industries. Whether it’s installation, maintenance or removal of electrical systems, footwear is an important an essential aspect of PPE that should be used. It is important to remember dielectric footwear or insulating footwear should not be used instead of other PPE, but as an additional protective item.

For working on EV and PHEV's insulated footwear should be worn when:

• First making the vehicle battery pack safe;
• Conducting tests to ensure the generator/ battery is isolated;
• Working on the battery pack or HV system;
• Reconnecting the battery pack to the vehicle;
• Conducting diagnostics of the HV system and connections.

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3 - Insulated Safety Footwear Ratings and Safety Guide

Electrically insulating footwear is tested at the appropriate leakage current test voltage for their class rating, (see table below), for three minutes during which the leakage current must not exceed the maximum permitted value for the class rating. For initial certification of a product, the shoe/ boot is tested to the withstand test voltage, but this is considered a destructive test.

As insulated safety footwear is also classed as safety footwear they will also meet the required standards of EN ISO 20345:2011.  These standards will include such things as slip resistance, toe protection, resistance to chemicals etc.

Warwick Test Supplies recommends Class 0 rated footwear for PHEV and EV Vehicle maintenance and diagnostics.

Class Rating	Maximum Working Voltage	Withstand Test Voltage	Leakage Current Test Voltage	Maximum Leakage Current
Class 00	500V	5kV	2.5kV	3mA
Class 0	1kV	10kV	5kV	5mA (8mA)
Class 1	7.5kV	20kV	10kV	10mA (16mA)
Class 2	17.5kV	30kV	20kV	18mA
Class 3	26.5kV	40kV	30kV	20mA
Class 4	36kV	50kV	40kV	24mA

4 - How to look after your Insulated Safety Footwear?

Improper use of insulated safety footwear can be a matter of life and death. To ensure full protection the footwear with insulated soles are to be looked after and maintained appropriately. It is recommended that users protect their footwear and clean their shoes as follows;

• Minimise the possibility of damaging the sole of the footwear by keeping the workplace and floor clean of debris;
• After use, clean the footwear of all types of dirt and debris, by brushing off any particles that have built up during the day;
• Leave the footwear open to dry, to ensure any perspiration or dampness evaporates without leaving them in direct contact with a heat source.

Storage

Storage conditions are an important preservation factor for the electrical and mechanical performances of shoes with insulated soles. Shoes with insulated soles should be stored in a box before their first use and between successive uses.

Sibille C960 Shoe

Sibille Insulated Footwear

Sibille C970 Workboot

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5 - Testing Your Insulated Safety Footwear

Before Use

Precautions and inspection before use is strongly recommended. Before use, the user must always carefully check that the shoes do not show any sign of deterioration, such as visible deep cracks in the upper, defective or split stitching, the presence of cracks or perforations on the outsole. Users must never wear a shoe/boot if there is visible deterioration, they are dirty or damp.

Periodic Inspection

Periodic Inspection consists of the user visually examining the footwear for any deterioration or defects.  It is a good idea to record and log these inspections. 

Testing

Insulated Shoes/ Boots must also be electrically tested every 12 months following their first use.  This can be done by a electrical testing laboratory who will issue a test certificate or it may be advantageous and/or cost effective to replace the footwear every 12 months.  

Obsolescence Period

Typically, the final obsolescence date of insulated footwear is 3 years from the date of marking shown on the shoe.

6 - EV Diagnostic Technician Footwear - Summary

Diagnostics and repair of EV and PHEV vehicles will always be associated with an electrical safety risk, as energised circuits pose threat to life from electrical shocks. Your footwear could be the last line of defence between you and a fatal electrical shock from the vehicles battery pack. However It's important to remember insulated safety footwear is only part of the PPE inventory that must be worn when conducting work on battery packs whilst maintaining or repairing EV/PHEV vehicles. 

Electrically insulated footwear is available in a number 'Classes' dependant on the level of voltage they are designed to protect against.  The appropriate Class of insulated footwear for working on EV/PHEV is Class 0.

Buyers Tips

- Buy Certified 1000V Class 0 Insulated Footwear from a reputable brand;

- Inspect the sole and shoe before every use;

- Class 0 Insulated Safety Footwear has a 12 month working life from date of first use before requiring an electrical test or be replaced.

Warwick Test Supplies stocks a range of insulated safety footwear in both shoe and boot styles that will meet the requirements of a technician working within a workshop.  See our range....

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Electrical Insulated Gloves are used to protect a user from electric shock when working on live high voltage electrical systems. There are many different variations of Electrical Insulated Gloves, categorised into one of 5 classes, dependant on the voltage levels that may be encountered and their electrical requirements. 

When working on Electric Vehicles (EV) or Plug in Hybrid Electric Vehicle (PHEV) there is a requirement to wear insulating gloves due to the voltages present in their battery packs. Voltages in battery packs on modern vehicles can be anywhere from between 300V and 900V and the correct gloves to wear are those that are categorised as Class 0. 

This guide will focus on Class 0 Insulated Gloves that are typically used in EV/PHEV vehicle diagnostics and repair. Discover answers to common queries and questions related to insulated gloves. 

1 - What are Insulated Electrical Gloves?

2 - When should insulated gloves be worn?

3 - How to look after your EV Gloves

4 - How to test your insulated Gloves

5 - Insulated Electric Gloves Summary

1 - What are Insulated Gloves?

2 - When Should Insulated Gloves been worn?

3 - How to look after your EV insulated gloves?

Improper use or care of electrically insulating gloves can be a matter of life and death. The gloves are generally manufactured from a rubber material and as such are susceptible to damage from sharp objects, dirt and grit. Top Tips on looking after your insulated gloves:

• Always keep your gloves in a storage case when not in use to minimise their exposure to a dirty environment and ultraviolet light.  Using a UV resistant case/bag bag is essential. The gloves are easily compromised and damaged from sun light, heat and ozone. The best option to keep your gloves safe is storing them in a hard-case.
• Do not store the gloves folded or rolled up.  Store them laid flat in their natural position.
• Do not store any other objects in the glove storage case, unless there is a specific compartment i.e for talc.
• Only wear the gloves when necessary during your work and avoid touching objects, benches, or the floor that may have dirt, dust, grit, grease, solvents or fuel on them.
• Wear leather over gloves over the top of the insulated gloves, especially when in a dirty environment or having to touch or be near sharp objects.
• If the gloves get dirty clean them as soon as possible using clean water and a small amount of mild detergent.  Rinse well afterwards and let the gloves dry naturally before placing back in a storage case.
• If the gloves may have been in contact with sharp objects or contaminated by grit or dirt test them before reuse.
• Inspect your gloves before each use and regularly test them to ensure they are fit for purpose and electrically safe.

Look after your electrically insulated gloves, store them in a decent case and they can easily last you 6-8 years.

Do Insulated Gloves have an expiry date?

Electrically Insulating Gloves have no expiry date. Providing the gloves comply with the period of inspection they remain fit for purpose.  For Class 0 insulated gloves this means a visual inspection before each use and regular inflation tests.  There is no requirement for Class 0 gloves to be regularly electrically tested, although is it recommended.

Sibille Hard Glove Case  

Sibille Hard Glove Case

Sibille Soft Glove Case

 4 - How to test your Insulated Gloves?

Inspection Before Use

A visual inspection of the gloves should be carried out before each use. Check for tears or nicks and pay close attention to potential pin pricks through the skin of the gloves.  If you discover any potential hole in the glove they will not provide adequate protection so must be replaced.

5 - Summary - Electrical Safety Gloves

Choosing the correct Class Rated gloves for your task, correct storage and inspection/ testing before use are 3 critical factors you must follow to ensure safe use of insulated gloves. Electrical testing and measuring will always be associated with risk as energised circuits pose threat of electrical shocks. Many times your insulated gloves are your last line of defence between you and a high-voltage shock. Improper use or care of electrically insulating gloves can be a matter of life and death. Use the Class Ratings table above to assess what level of protection is required and be sure to understand the gloves label and markings before exposing them to any usage. If you have any queries or unclear on what gloves best suit your application contact Warwick Test Supplies for advice and product suggestions. 

Electrical test probes are used to create a temporary connection between an electrical circuit under test and a measuring instrument, often a digital Multimeter. There are several types of test probes and this short article identifies the different types of test probes, as well as offering guidance on what test probe connector suits your specific application.

1 - What are Test Probes?

2 - Test Probe Safety and CAT Ratings?

3 - How to Choose your Test Probe

4 - How to Choose your Fused Test Probes

5 - Understand new Test Probe IEC Standards

1 - What Are Test Probes?

Test probes are a useful tool box accessory for any electrical testing or measurement purposes. Test probes can enable the operator to measure; voltage, current, resistances, temperatures and signals. There are many types of probes designed for specific measurement tests and situations, popular types of test probes include;

• Point/Needle/Lantern Tip Point Probes – Commonly seen as the standard test probe. The needle point tip enables the operator to precisely locate the correct location for testing. Some needle point test probes can pierce cable insulation for testing without causing damage. Connections can also be made through banana connectors for a swift and secure connection (known as back-pinning – read full article for more information.)
• Hook/Pincer Style Probes – Test probes with hooks, pincers or grabber style connectors. These probes create a hands-free temporary connection to the component or wire under test with ease. Frequently used in automotive diagnostics and other electrical sectors where the connection point is inaccessible or hand-free connection is essential
• Fused Test Probes – Feature a built-in fuse within the test probe that provides an additional layer of protection to the individual connecting to a circuit and undertaking an electrical measurement. Fused test probes are used in many high-voltage applications. For more information > Why use Fused Test Probes or Leads?

Lantern Tip Probes

Pincer/Grabber Probes

Fused Test Probes

2 - Test Probe Safety and CAT Rating

Choosing the ‘best’ probe is about matching your requirements with the test probe specification. It’s similar to buying a car, buying a two-seater convertible isn’t appropriate if you’re a tradesman that needs a van to travel tools and materials.

Assessing the electrical circuits and intended application is a good place to start before buying test probes. The CAT rating concept is linked to the distance you are from the source of the supply. The closer to the source, the higher the CAT Rating you need to perform any electrical testing. Using Fluke’s guide on CAT Ratings is a useful point of reference;

3 - How to Choose Your Unfused Test Probe?

Once you've identified and assessed the CAT Rating required for your application you can narrow your test probe search. Remember the length of the test probe tip (exposed metal) typically signifies the CAT Rating. The shorter the tip the less likely of an accidental arc (CAT II – 19mm Test Probe Tip - CAT III and IV – 4mm Test Probe Tip).  

CAT II 1000V

Test probes suitable for; appliances, portable tools, and other household items;

PJP 590-IEC

PJP 490-IEC

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CAT III 1000V / CAT IV 600V

Test probes suitable for; three-phase distribution, including single-phase commercial lighting

PJP 404-IEC

PJP 370-IEC

PJP 380-IEC

CAT IV 1000V

Test probes suitable for three-phase at utility connection and any outdoor conductors

PJP 402-IECIV

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4 - How to Choose your Fused Test Probe

Fused Test Probes protect the operator from harm. Electrical Test Instruments like digital multimeters are protected internally by high intensity fuses and clearance distances appropriate to the installation category and voltage ratings of an instrument. The fused test probes are sold with a specific fuse installed. The test probes are printed with the voltage and current related to the specifications of the chosen fuse and according to EN / IEC 61010-031:2015. The current value is the fuse rated current. The voltage value is the voltage of the probe plus fuse combination.

CAT II 1000V - Fused Test Probes

Test probes suitable for; appliances, portable tools, and other household items. There are many fuses available with different voltage and Amp ratings. Ensuring your fuse ratings are suitable for your circuit or appliance is essential before connecting and running measurement tests. 

PJP 590-IEC-Fuse

PJP 490-IEC-Fuse

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CAT III 1000V / CAT IV 600V

 Test probes suitable for; three-phase distribution, including single-phase commercial lighting

PJP 370-IEC-Fuse

PJP 380-IEC-Fuse

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5 - Test Probes Updated IEC Standards

Whether you’re using an oscilloscope or a Multimeter, having the correct probe is important not only for measuring, but for the safety of the test.

The latest standards BS EN 61010-031:2015 came into force July 2018. It specifies safety requirements for hand-held and hand-manipulated probe assemblies and their related accessories. The amended safety standard was enforced to offer test probe operators improved safety when electrical testing.

• The EN 61010-031:2015 standard requires coherence between the safety from the fuse and the safety from the fuse-folder probe.
• The EN / IEC 61010-031:2015 requires manufacturer shows the safety specifications without any misunderstanding

Get a FREE Fluke tool with purchases starting at £200.00

How To Receive Your Free Tool from Fluke

Spend £200 or more on any qualified Fluke product between 15 February 2021 and 30 June 2021.

• Purchases must be made from an authorised Fluke Distributor based in the United Kingdom.
• End user must be based in the United Kingdom
• Proof of sale in the form of a single receipt or invoice is required. Packing slips, purchase orders/order confirmation are not acceptable as proof of purchase.
• Only Fluke IG, Fluke Calibration or Fluke Networks products are eligible for this promotion.

Redeem your gift online! Visit: fluke.co.uk/freefluke

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1 - What is 'Buy a Fluke. Get A FREE Fluke' Campaign?

2 - How does the 'Buy a Fluke. Get a FREE Fluke' Campaign work?

1 - What is 'Buy a Fluke. Get a FREE Fluke' Campaign?

Fluke launches its biggest promotion ever from 15 February to 30 June 2021. It's for all those electricians, service technicians, maintenance managers, meteorologists, networking engineers, data cabling technicians and many more individuals that have kept the world running during the restrictions and difficulties from Covid-19.  

Receive a FREE Fluke product when you buy a Fluke product from Warwick Test Supplies. Read the guide below for more information on FREE Fluke product choices.

2 - How does 'Buy A Fluke. Get A FREE Fluke' Work?

Buy a Fluke product from Warwick Test Supplies and then submit your receipt to Fluke online and pick your FREE Fluke tool. Depending on the amount you spend, you have a choice from four different FREE Fluke products, which are then delivered to your door. 

to Make Your Claim Visit: fluke.co.uk/freefluke  

• Purchases must be made from an authorised Fluke Distributor based in the United Kingdom
• End user must be based in the United Kingdom.
• Proof of sale in the form of a single receipt or invoice is required. Packing slips, purchase orders/order confirmation are not acceptable as proof of purchase.
• Only Fluke IG, Fluke Calibration or Fluke Networks products are eligible for this promotion.

Vehicle diagnostics involves measuring power and electrical signals with a Digital Multimeter, Oscilloscope or other test equipment. To make connections to conduct diagnostic tests, technicians often use Back-Pin Probes or specific Connector Breakout Leads to connect to sensors or actuators to gather diagnostic information. Discover below the advantages and disadvantages of both diagnostic connection methods so that you can make an informed judgement on what is more appropriate for the diagnostic tests that you conduct.

1 - What is Back-Pin Probing?

2 - What Are The Advantages of Back-Pin Probing?

3 - What Are The Disadvantages of Back-Pin Probing?

4 - What Are The Automotive Connector Breakout Leads?

5 - What Are The Advantages of Vehicle Diagnostic Breakout Leads?

6 - What Are The Disadvantages of Vehicle Diagnostic Breakout Leads?

7 - Conclusion

1. What is Back-Pin Probing?

2. What are the Advantages of Back-Pin Probing?

• Back-Pin Probing eliminates the need to puncture or pierce wire insulation to test the circuit. This safe guards wire insulation integrity and prevents comprising vehicle looms performance and longevity.
• Many Back-Pin probes offer the capability to replace broken or damaged pins at the front of the probe. Replacing damaged pins is fairly easy and cost effective preventing the replacement of the whole probe.
• Technicians are able to test and measure a wide range of automotive connectors with Back-Pin probes. Connections are made without the need of specific connector breakouts. They are versatile, cost effective and useful across different vehicle models and manufactures.

3. What are the Disadvantages of Back-Pin Probing?

• If used without care or having test leads attached to the Back Pin can often cause adjacent probes to touch each other, resulting in a short circuit and circuit damage. The damage can be difficult to trace and further complicates the diagnosis. Circuit damage can be costly in added time and loom replacements. Back-pinning may invalidate the manufacturers warranty on wiring looms and connectors. To mitigate warranty complications many use designated breakouts that comply and prevent loom damage.  
• Back Pinning often damages the weather seals on the connector or the internal terminal. Damage to the weather seals encourages ingress of moisture and dust that leads to corrosion and eventually results in connection and signal failure. New connectors aren’t particularly costly but they can be difficult to accurately identify and source with thousands of variations on the market.
• Back Probing is often associated with unreliable and poor electrical connections. There is high risk of a weak and unreliable connection as the probe is inserted through the back of a connector without certainty of creating a secure and positive connection. It is reliant on touch alone with the amount of pressure/ resistance varying when subjected to vibration etc.  Unreliable measurement readings often cause misdiagnosis and unsuccessful fault finding. 
• Deploying a back-pin into a connector can be difficult when the connector is difficult to access.  This increases the risk of damage or a poor connection. 

4. What are Automotive Connector Breakout Leads?

5. What are the advantages of Vehicle Diagnostic Breakout Leads?

• Breakout leads are designed to create an in-line circuit and offer easy access to output signals and individual wires. Versatile set-up enables technicians to have easy access to diagnose individual wires for voltage and current for specific test and measurement tasks. Readings and waveform capture is fast, effective and reliable. 
• Vehicle connector breakouts offer a secure and reliable connection just as the manufacturer had designed. The male plug and female socket locates and connects to the chosen vehicle connector/sensor. The connection simulates the vehicles exact working electrical connection. 
• Vehicle Connector Breakout Leads manufactured by Warwick Test Supplies are built in the UK using IEC rated components and OEM connectors offering hard-wearing performance for the workshop.

Breakout Leads By Brand

Discover reliable and hard wearing automotive connector breakout leads compatible with the vehicle brands below; 

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6. What Are The Disadvantages Of Vehicle Diagnostic Breakout Leads?

• Vehicle Manufacturers use a plethora of different vehicle connectors. There is not a 'one lead fits all' approach, each vehicle connector requires a designated breakout lead. Vehicle Breakout Leads are sold separately or in brand specific kits. A VAG Connector Breakout Lead Kit for example, covers the majority of Volkswagen, Audi and Skoda vehicles.
• Automotive Connector Breakout leads are costly, in comparison to back-pin probes but last exponentially longer. However, fast connections and reliable readings help improve fault finding efficiency, reducing diagnostic labour time and overall costs. 

7. Breakout Leads Vs. Back-Pin Probes - Conclusion

Technicians that perform advanced automotive electrical diagnostic tests using oscilloscopes and test equipment rely on; fast, secure and safe connections to perform test and measurement readings. Back-pin probes partly satisfy these needs, but connection security is often questioned and inadvertent damage to either the connector or cable loom circuit is a realistic concern as it can invalidate manufacturers warranty. That said, back-pins are cheap and used correctly can offer a versatile option that can be used on majority of connectors and different vehicles. 

Diagnostic breakout leads are fast and easy to connect to vehicle sensors and actuators enabling easy access to wires to test. They provide a secure and reliable connection without compromising connector weather seals, terminals or risk shorting circuits. Breakout leads are a costlier alternative to back-pins, but there functionality and performance is arguable money well spent and their longevity will outlast multiple replacements of back-pins. Many have said they speed up diagnostics and improve working efficiency.