Automotive Surge Protection and Electronic Protection Devices

Frequently Asked Questions About Automotive Surge Protection and Electronics Protection

Modern vehicles contain numerous electronic components that can be sensitive to harmful voltage spikes. The following questions explain when automotive surge protectors are used, how the devices for 12- and 24-volt electrical systems differ, and what the limitations of these protectors are.

• What is a vehicle surge protector?

  An automotive surge protector is designed to protect electronic components in a vehicle from voltage spikes or elevated voltages in the vehicle electrical system.

  The ES 01 and ES 02 electronic protection devices from Autotestgeräte Leitenberger are connected directly to the vehicle battery and absorb any high voltages that may occur during designated workshop procedures.

  They are part of the Test and Diagnostic Equipment for Automotive Electrical Systems.

• When is an electronic protection device used on a vehicle?

  The ES 01 and ES 02 electronic safety devices are specifically designed for situations in which undesirably high voltages may occur while working on a vehicle.

  Leitenberger explicitly lists the following examples:

  • Welding work on the vehicle
  • Charging the vehicle battery

  Before use, the specifications of the vehicle manufacturer and the workshop equipment being used must be taken into account.

• Why is surge protection important when performing welding work on a vehicle?

  Welding operations can generate electrical interference pulses or voltage spikes.
  
  A suitable electronic protection device limits or absorbs such high voltages as they occur, thereby helping to protect electronic components in the vehicle.
  
  The vehicle manufacturer’s specifications for welding operations always take precedence.

• Can surge protection be used when charging a built-in car battery?

  Yes. According to Leitenberger, the ES 01 and ES 02 are also designed to absorb high voltages that occur when charging the vehicle battery.

  Battery and charging system testers are also available to evaluate the battery, alternator, and starter/charging system.

• Which vehicle electronics are protected by an electronic protection device?

  These devices are generally intended to protect electronic components in motor vehicles from the voltage spikes described.
  
  However, the specific control units and electronic components present in a given vehicle—as well as the required protective measures—vary depending on the vehicle.
  
  Therefore, the repair and manufacturer specifications for the specific vehicle must always be taken into account as well.

• What is the difference between ES 01 and ES 02?

  The most important difference is the permissible voltage range.

  ES 01:

  • for 12-V systems
  • Voltage suppression above 15 V

  ES 02:

  • for 12-V and 24-V systems
  • Automatic voltage detection
  • Voltage suppression above 25 V

  For repair shops that work on both 12-V and 24-V vehicles, the ES 02 thus offers a wider range of applications.

• Which surge protector is suitable for 12-volt vehicles?

  Both the ES 01 and the ES 02 can be used for pure 12-V vehicle electrical systems.
  
  The ES 01 was developed exclusively for 12-V systems.
  
  The ES 02, on the other hand, supports both 12-V and 24-V systems and automatically detects the vehicle voltage.

• Which electronic protection device is suitable for 24-volt commercial vehicles?

  The ES 02 is designed for 24-V electrical systems.
  
  Thanks to its automatic voltage detection, it can be used in both 12-V and 24-V systems.
  
  This makes it suitable for corresponding applications in commercial vehicles with 24-V electrical systems.

• Does the ES 02 automatically detect whether a vehicle has a 12-volt or 24-volt system?

  Yes. The ES 02 features automatic voltage detection for 12- and 24-volt systems.
  
  This eliminates the need to switch between two different device models when working on vehicles with different on-board voltages in a workshop.

• How do you connect a vehicle surge protector?

  The ES 01 and ES 02 are equipped with battery terminals and are connected to the vehicle battery.
  
  The connection must be made in accordance with the device instructions and with the correct polarity.
  
  In addition, the vehicle manufacturer’s safety and repair guidelines must be followed.

• Do you still need to disconnect the car battery when welding?

  There is no one-size-fits-all answer for every vehicle.
  
  An electronic protection device is designed to limit or absorb voltage spikes. However, it does not replace the operating and safety guidelines provided by the respective vehicle manufacturer.
  
  If the vehicle manufacturer requires that the battery be disconnected or that other measures be taken for certain welding operations, these guidelines must be followed.

• Is an electronic protection device the same thing as a voltage regulator?

  No. These two types of devices serve different primary purposes.

  An electronic or surge protection device protects electronic components from unwanted voltage spikes.

  A voltage maintenance device, on the other hand, continues to supply electrical power to the vehicle's electrical system during certain maintenance tasks, such as when the vehicle battery is being replaced. Suitable devices can be found in the Emergency Power Supply and Voltage Maintenance section.

• Why is the NSV 03/1 both an electronic protection device and a voltage maintenance device?

  The NSV 03/1 combines both functions.
  
  It can supply power to a 24-V vehicle electrical system via an external 24-V power source during battery replacement to prevent the loss of electronic data.
  
  In addition, it features surge suppression to protect the vehicle's electronics during relevant work.

• Can the NSV 03/1 also be used on 12-volt vehicles?

  The NSV 03/1 is specified for a 24-V vehicle electrical system and an external 24-V power supply.
  
  Other devices are available for 12-V applications.
  
  A device’s voltage range must therefore always match the vehicle’s electrical system.

• Is a vehicle surge protector the same as a battery charger?

  No.

  ES 01 and ES 02 do not generate a charging current and are not intended to charge the vehicle battery.

  Their purpose is to absorb high voltages or voltage spikes that may occur during specific tasks.

  Battery and charging system testers are designed for testing the vehicle battery and the charging system.

• Can the ES 01 and ES 02 be used in electric and hybrid vehicles?

  The ES 01 and ES 02 are devices designed for 12-volt and 12/24-volt vehicle electrical systems, respectively. They are not high-voltage protection or high-voltage test devices.

  For electric and hybrid vehicles, it is therefore essential to clearly distinguish between the low-voltage electrical system and the high-voltage system.

  Work on the high-voltage system requires appropriately suitable testers for electrical safety on electric and hybrid vehicles, as well as the required qualifications and safety measures.

• Does a surge protector supersede the vehicle manufacturer's specifications?

  No.
  
  An electronic protection device is an additional piece of workshop equipment intended for the specified area of application.
  
  The vehicle manufacturer’s work instructions—particularly those regarding welding, battery charging, disconnecting the battery, or working on electrical or electronic systems—must still be followed.

• Are there replacement fuses for the ES 01 and ES 02?

  Yes. For ES 01 and ES 02, the replacement fuse ET 302 (121198), 3.15 A is available.

  This can be used to replace the electronic protection device's standard fuse if necessary.