HV insulation resistance test
Mandatory safety test for high-voltage isolation.
A high-voltage insulation resistance test (megger) verifies that every HV component in your EV is properly isolated from chassis. Mandatory after any HV component swap, post-collision, post-flood, or before resale of older vehicles. The pass/fail certificate is accepted by most insurers for monsoon flood claims.
What's included
- 500V/1000V megger test on all HV legs
- Chassis isolation verification
- Contactor seal inspection
- Pass/fail safety certificate
Why this matters
An isolation failure between HV and chassis is the #1 EV electrical safety hazard. A passing megger today doesn't mean it'll pass after the next monsoon — but driving with a failed isolation is genuinely dangerous.
How it works
- 1
Vehicle in safe state, HV system de-energized via service plug.
- 2
500V/1000V megger applied between each HV leg and chassis.
- 3
Contactor seal inspection.
- 4
Document readings (MΩ values), issue pass/fail certificate.
What to expect
Allow 60 minutes. Certificate issued same day, valid 90 days. Failures are common after flood events — we'll quote the remediation but won't force you to do it with us.
What we typically find
From hundreds of inspections — what makes the report.
- Marginal isolation after monsoon (often dries out and passes on re-test)
- Contactor seal swelling (replacement quoted)
- Charge-port HV pin moisture contamination
How to prepare
- Note any recent flood, collision, or HV component work
- Vehicle should be dry — if wet, we'll reschedule
Equipment we use
- Megger MIT525 (500V/1000V)
- OEM-spec HV service-plug procedure
Certifications
- HV-safety trained team
- Certificate accepted by major insurers
Transparent pricing breakdown
No hidden charges. This is exactly what makes up your bill.
Bench time + HV safe-state setup | ₹1,500 |
Megger test + certificate | ₹999 |
| Total | ₹2,499 |
What customers say
“Insurance accepted the megger certificate without question. Fast turnaround.”
FAQs
Required by law?+
Not strictly, but most insurers ask for it after flood/collision claims.
How long?+
Around 1 hour.
Home or workshop?+
Workshop — high-voltage testing demands controlled environment.
Who needs this
Post-flood EVs, post-accident vehicles, before resale, after HV component swap.
Related services
Ready to book hv insulation resistance test?
Fixed price ₹2,499 — no surprises. Or describe a different problem and we'll match the right service.