Leak Testers for HV Batteries and High-Voltage Components

Professionally test high-voltage battery housings and high-voltage components for leaks! The housing of a high-voltage battery protects the battery cells, electronics, and other components from external factors such as moisture and dirt. After certain repair, disassembly, or maintenance work, a high-voltage battery leak test may therefore be required in accordance with the vehicle manufacturer’s specifications.

Autotestgeräte Leitenberger offers professional leak testers for high-voltage batteries and other HV components in electric and hybrid vehicles. Depending on the tester and manufacturer’s specifications, tests can be performed using overpressure or vacuum, as well as using the pressure drop method or the flow or mass flow method.

For pressure drop testing, various digital testers are available for different measurement and pressure ranges. The DFG 50 and DFG 200 flow meters can also be used to determine very small air flows or leak rates. The LTA 01_LR automatic tester enables programmable test sequences using pressure change and flow methods, as well as the documentation of test results.

If a leak is to be not only detected but also precisely located, the LTBG 04 can be used to introduce tracer gas into a suitable test specimen, after which a suitable leak detector can be used to search for escaping tracer gas.

In addition to HV battery housings, other high-voltage components—such as inverters, DC/DC converters, on-board chargers (OBCs), electric drives, or HV air conditioning compressors—can also be tested for leaks, depending on the component and manufacturer’s specifications.

For HV batteries with pressure-equalization elements, special tools, test caps, and test adapters are also available. This allows the battery to be prepared in accordance with the respective test specifications and a defined test pressure to be introduced into or maintained within the battery housing.

Test pressure, vacuum, test duration, stabilization time, and permissible limits are not universal. The specifications provided by the vehicle or component manufacturer are always decisive.