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AVL DiTEST HV Safety 2000

Table of contents

User manual

VII

Table of contents

IMPORTANT SAFETY INSTRUCTIONS ......................................................... I

Warning and safety instructions ................................................................. II

Summarised safety notes ............................................................................III

Safety notes .................................................................................................. V

General ............................................................................................. 1-1

General description .......................................................................................................... 1-1

Safety instructions ............................................................................................................ 1-2

Typographical conventions .............................................................................................. 1-2

Operation of PC programs ............................................................................................... 1-3

Design .............................................................................................................................. 1-4
1.5.1

Overview ........................................................................................................ 1-4

Top side ......................................................................................................... 1-5

Test adapters ................................................................................................. 1-6

Probe tips ....................................................................................................... 1-7

Commissioning ............................................................................... 2-1

Hardware ......................................................................................................................... 2-1

Software .......................................................................................................................... 2-1

Data entry and settings .................................................................................. 2-2

Settings for HV Safety.................................................................................... 2-2

Performing a measurement ............................................................ 3-1

Results protocols ............................................................................................................. 3-2
3.1.1

Editing and printing results protocol ............................................................... 3-2

All-pole DC voltage measurement ................................................................................... 3-3

DC Voltage measurement ............................................................................................... 3-4

HV insulation measurement ............................................................................................. 3-6

Equipotential bonding check ............................................................................................ 3-8

Resistance measurement .............................................................................................. 3-10

Diode test ....................................................................................................................... 3-12

Capacity measurement .................................................................................................. 3-14

Insulation monitor check ................................................................................................ 3-16

SAE J1766 measurement .............................................................................................. 3-18

Full measurement .......................................................................................................... 3-20

Troubleshooting .............................................................................. 4-1

Introduction ...................................................................................................................... 4-1

Error messages ................................................................................................................ 4-1

Function test .................................................................................................................... 4-2
4.3.1

DC Voltage measurement ............................................................................. 4-2

HV insulation measurement ........................................................................... 4-2

SAE J1766 measurement .............................................................................. 4-2

Full measurement .......................................................................................... 4-2

Resistance measurement .............................................................................. 4-2

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Summary of Contents for DITEST HV SAFETY 2000

Page 1: ...USER MANUAL AVL DITEST HV SAFETY 2000 ID no AT7718E Revision 05 Edition 12 2018 Data subject to change withoutnotice Alldatavalidat thetimeofgoingtoprint FUTURE SOLUTIONS FOR TODAY ...

Page 2: ... rights reserved The contents of this publication as a whole or in part may not be reproduced in any form or passed on to third parties without the prior written consent of AVL DiTEST This publication was written exercising reasonable care AVL DiTEST can therefore not accept any liability whatsoever for any errors or omissions as well as for any possible damage ...

Page 3: ...se Never use the cord to pull the plug from the outlet Grasp plug and pull to disconnect Let equipment cool completely before putting away Loop cord loosely around equipment when storing To reduce the risk of fire do not operate equipment in the vicinity of open containers of flammable liquids gasoline Adequate ventilation should be provided when working on internal combustion engines Keep hair lo...

Page 4: ...e required safety measures when using and operating the equipment It may only be operated with the accessories and consumables supplied by DITEST or approved by DITEST Since with this product the measuring results not only depend on proper functioning of the product but also on a number of further conditions it is necessary to have the results generated by the product checked e g plausibility chec...

Page 5: ...ile engine is running Danger of electric shock on vehicles with xenon headlight The lighting system with xenon headlight is under life threatening high voltage Do not touch any component while the xenon light is switched on Danger due to harmful or irritating substances Tests with engine running in closed rooms workshops test halls etc the exhaust emission has to be vented to the outside and the s...

Page 6: ...ion only with approved testing device Disconnect the battery when working on the airbag system When disconnecting the battery the ignition has to be switched off and there should be nobody in the passenger compartment Always store dismounted airbag unit with discharge area up or according to the storage instructions Airbag unit should never be left unattended Protect airbag unit against flying spa...

Page 7: ...s applied to the HV energy store HV battery and the connected parts Make sure that no one gets in contact with hybrid battery terminals the connecting cables of the HV battery and other live parts Danger of death from electrical voltage in vehicles with high voltage systems Special safety and training conditions apply for work under voltage Make sure to observe these safety conditions in every sit...

Page 8: ...urrent which is limited to 2mA is not life threatening After high voltage insulation measurement the high voltage at the test tips is automatically reduced due to the measuring module Danger of death from electrical voltage in vehicles with high voltage systems During the high voltage insulation measurement the measured object must be de energized Before measuring disconnect the HV energy store HV...

Page 9: ...2 2 2 2 1 1 Settings for HV Safety 2 2 3 Performing a measurement 3 1 3 1 Results protocols 3 2 3 1 1 Editing and printing results protocol 3 2 3 2 All pole DC voltage measurement 3 3 3 3 DC Voltage measurement 3 4 3 4 HV insulation measurement 3 6 3 5 Equipotential bonding check 3 8 3 6 Resistance measurement 3 10 3 7 Diode test 3 12 3 8 Capacity measurement 3 14 3 9 Insulation monitor check 3 16...

Page 10: ...y 6 1 6 1 New devices 6 1 6 2 Exchange or loaned devices 6 1 6 3 Event of damage or loss 6 1 7 Technical data 7 1 7 1 CAT overvoltage categories 7 1 7 2 Operating data 7 3 7 3 Metrology specifications 7 4 7 3 1 DC Voltage measurement 7 4 7 3 2 SAE J1766 insulation measurement 7 4 7 3 3 High voltage insulation measurement 7 5 7 3 4 Equipotential bonding check 7 5 7 3 5 Resistance measurement 7 6 7 ...

Page 11: ...he DC voltage HV insulation resistance and SAE J1766 measurements into one user guided procedure Equipotential bonding check Resistance measurement Diode test Capacity measurement Insulation monitor check Features Parameterisation by configurable test voltage 250 to 1 000 volts nominal test current 1 mA Generation of high voltage enablement only at press of a button automatic discharge of transien...

Page 12: ...ly dangerous risk which if not prevented leads to death Indicates an imminent danger if not prevented can result in death or serious injury Indicate a danger that may lead to moderate or light injuries Additional danger signal Danger due to electrical current Notes This text draws attention to situations or operating error that can lead to property damage or loss of data This text indicates import...

Page 13: ...ditions Menu Menu item Selection of menu command through tapping on buttons List formats 1 2 Step by step instructions in a specified sequence Instructions consisting of only one step Listings without a specific order 1 4 Operation of PC programs This manual assumes basic knowledge of Microsoft Windows Please turn to your Windows manual for details If necessary contact your PC support system admin...

Page 14: ...o cover the black probe tip 4 Black probe tip to connect to the black test adapter 5 Red protective cap to cover the red probe tip 6 Red probe tip to connect to the red test adapter 7 Protection against accidental contact for red test adapter 8 Button on red test adapter 9 Red test adapter 10 Protection against accidental contact for black test adapter 11 Black test adapter 12 USB connector Fig 1 ...

Page 15: ...operation Fast flashing Error e g no firmware in device Green Lit Normal operating condition Slow flashing Self test in progress Fast flashing Waiting for press of button to start self test Red green Off Firmware update with bootloader in progress Red Green Blue Lit Off Lit Voltage 10 V present at probe tips test voltage or high voltage generated by the AVL DiTEST HV Safety 2000 Fig 1 2 1 2 1 2 ...

Page 16: ... 300V Measurements in electric circuits that are connected directly to the mains are not permitted For this reason use the AVL DiTEST HV Safety 2000 only for measurements on the vehicle The 3 m test cables are permanently connected to the test adapters and the AVL DiTEST HV Safety 2000 The red test adapter has a button that is used to start various actions Fig 1 3 Protection against accidental con...

Page 17: ...ected directly to the mains are not permitted For this reason use the AVL DiTEST HV Safety 2000 only for measurements on the vehicle Danger of death from electrical voltage Please note that only measurement equipment which was delivered from AVL DiTEST will be used When using general measuring adapters probe tips test clips please note that these are suitable and approved for measuring and test vo...

Page 18: ...General AVL DiTEST HV Safety 2000 1 8 User manual ...

Page 19: ...rks only in conjunction with AVL DSS version 2 3 2700 0 or higher To be able to use the AVL DiTEST HV Safety 2000 you must 1 Install AVL DSS 2 3 2700 0 if no version of AVL DSS is installed on your PC Proceed as described in section 1 AVL DSS installation of the AVL DSS brief instruction 2 Update AVL DSS to version 2 3 2700 0 if an older version is installed on your PC Proceed as described in sect...

Page 20: ... conductor option is enabled with the AVL DiTEST HV Safety it is necessary to enter the conductor s name at the start of the measurement procedure The conductor is entered under the item Settings Workshop Persons By clicking on Enter password the conductor can enter his her name and set a password Vehicle identification If Vehicle identification enabled is enabled the vehicle identification dialog...

Page 21: ...e section 3 7 Capacity measurement see section 3 8 Insulation monitor check see section 3 9 SAE J1766 measurement see section 3 103 5 Full measurement see section 3 113 11 3 Clicking on in the HV Safety window closes AVL DiTEST HV Safety 2000 4 Clicking on in the DSS Manager window closes AVL DSS Danger of death from electrical voltage Make sure that no other devices with an earth connection are c...

Page 22: ...d automatically after each measurement 3 1 1 Editing and printing results protocol After a measurement click F6 Report to display the results protocol F3 Identification Vehicle identification will appear F4 Print Prints the result protocol F5 Edit This is where you can edit the results protocol enter comments and display workshop and vehicle data yes no F5 Apply Quits results protocol editing F6 S...

Page 23: ...obe tips briefly Press and hold the test button on the red test adapter until the safety test has completed The result of the safety test is displayed 4 Place the probe tips on the test object 5 Press and hold the test button on the red test adapter until a stable measured value is displayed 6 The result of the measurement is displayed see Fig 3 2 If the test button is not kept pressed for long en...

Page 24: ...ly Press and hold the test button on the red test adapter until the safety test has completed The result of the safety test is displayed 4 Place the probe tips on the test object 5 Press and hold the test button on the red test adapter until a stable measured value is displayed 6 The result of the measurement is displayed see Fig 3 3 If the test button is not kept pressed for long enough the follo...

Page 25: ...t adapter 8 Clicking on F6 Report creates a report of the measurement results see chapter 3 1 9 Clicking on Cancel cancels the voltage measurement If no stable measured value is displayed Start a new measurement Press and hold the test button on the red test adapter until a stable measured value is displayed If necessary restart AVL DiTEST HV Safety 2000 or AVL DSS NOTICE ...

Page 26: ... the safety test has completed The result of the safety test is displayed 4 Select the HV measuring range Observe the nominal HV on board voltage of the vehicle under test 5 Observe the safety instructions that appear on the screen 6 Click on F8 Next 7 Place the probe tips on the test object 8 Press and hold the test button on the red test adapter until a stable measured value is displayed 9 The r...

Page 27: ...adapter 11 Clicking on F6 Report creates a report of the measurement results see chapter 3 1 12 Clicking on Cancel cancels the HV insulation measurement If no stable measured value is displayed Start a new measurement Press and hold the test button on the red test adapter until a stable measured value is displayed If necessary restart AVL DiTEST HV Safety 2000 or AVL DSS NOTICE ...

Page 28: ... specifications of the vehicle manufacturer specifications according to ECE Regulation R 100 4 The AVL DiTEST HV Safety 2000 zero adjustment is carried out Place the tips of the probe at the 0 ohm zero point marker aid blue cable clip Press and hold the test button on the red test adapter until the zero adjustment has completed The result of the zero adjustment is displayed If Kelvin terminals are...

Page 29: ...adapter 9 Clicking on F6 Report creates a report of the measurement results see chapter 3 1 10 Clicking on Cancel cancels the measurement If no stable measured value is displayed Start a new measurement Press and hold the test button on the red test adapter until a stable measured value is displayed If necessary restart AVL DiTEST HV Safety 2000 or AVL DSS NOTICE ...

Page 30: ...VL DiTEST HV Safety 2000 zero adjustment is carried out Place the tips of the probe at the 0 ohm zero point marker aid blue cable clip Press and hold the test button on the red test adapter until the zero adjustment has completed The result of the zero adjustment is displayed 4 Place the probe tips on the test object 5 Press and hold the test button on the red test adapter until a stable measured ...

Page 31: ... the measurement results see chapter 3 1 9 From the list under Select range selection the measurement range can be set for the next measurement 10 Clicking on Cancel cancels the measurement If no stable measured value is displayed Start a new measurement Press and hold the test button on the red test adapter until a stable measured value is displayed If necessary restart AVL DiTEST HV Safety 2000 ...

Page 32: ...ty instructions 2 Click on F8 Next 3 The AVL DiTEST HV Safety 2000 safety test is carried out Connect the probe tips briefly Press and hold the test button on the red test adapter until the safety test has completed The result of the safety test is displayed 4 Place the probe tips on the test object 5 Press and hold the test button on the red test adapter until a stable measured value is displayed...

Page 33: ... adapter 8 Clicking on F6 Report creates a report of the measurement results see chapter 3 1 9 Clicking on Cancel cancels the measurement If no stable measured value is displayed Start a new measurement Press and hold the test button on the red test adapter until a stable measured value is displayed If necessary restart AVL DiTEST HV Safety 2000 or AVL DSS NOTICE ...

Page 34: ...2 Click on F8 Next 3 The AVL DiTEST HV Safety 2000 safety test is carried out Connect the probe tips briefly Press and hold the test button on the red test adapter until the safety test has completed The result of the safety test is displayed 4 Place the probe tips on the test object 5 Press and hold the test button on the red test adapter until a stable measured value is displayed 6 The result of...

Page 35: ... the measurement results see chapter 3 1 9 From the list under Select range selection the measurement range can be set for the next measurement 10 Clicking on Cancel cancels the measurement If no stable measured value is displayed Start a new measurement Press and hold the test button on the red test adapter until a stable measured value is displayed If necessary restart AVL DiTEST HV Safety 2000 ...

Page 36: ...is displayed 4 Attach the test leads to HV and the chassis as shown on the screen 5 Repeat DC voltage measurements with varying internal resistance a Press the test button to start the DC voltage measurement for each internal resistance for the device as indicated on the screen b If the insulation monitor has tripped press Cancel This will take you to the end result Point 6 The triggering of the i...

Page 37: ...s see chapter 3 1 8 Clicking on F8 Next cancels the measurement 9 Clicking on Cancel cancels the measurement If no stable measured value is displayed Start a new measurement Press and hold the test button on the red test adapter until a stable measured value is displayed If necessary restart AVL DiTEST HV Safety 2000 or AVL DSS NOTICE ...

Page 38: ... measurement is displayed If the test button is not kept pressed for long enough the following message will appear Measurement invalid Test button released too early If this happens start a new measurement Press and hold the test button on the red test adapter until a stable measured value is displayed 10 Select internal resistance Select the internal resistance of the meter to be used for measure...

Page 39: ...s and hold the test button on the red test adapter to return to item 11 Insulation measurement HV against Chassis 19 Cancel cancels the SAE J1766 measurement mode If no stable measured value is displayed Start a new measurement Press and hold the test button on the red test adapter until a stable measured value is displayed If necessary restart AVL DiTEST HV Safety 2000 or AVL DSS NOTICE ...

Page 40: ...VL DiTEST HV Safety 2000 safety test is carried out Connect the probe tips briefly Press and hold the test button on the red test adapter until the safety test has completed The result of the safety test is displayed 3 Proceed as instructed on the screen As the procedure is menu driven a detailed description is not provided here Please refer to the description for the Voltage measurement HV insula...

Page 41: ...ect the AVL DiTEST HV Safety 2000 from the USB connection on the AVL MDS PC wait a few seconds and then reconnect it Error message Solution description A timeout occurred Repeat the measurement Firmware not running run mode Quit the current measurement function and restart A transient current occurred Repeat the measurement A transient voltage occurred Repeat the measurement Error during self test...

Page 42: ...3 3 SAE J1766 measurement To test the SAE J1766 measurement function of the AVL DiTEST HV Safety 2000 proceed as follows Test the AVL DiTEST HV Safety 2000 by performing an SAE J1766 measurement on a vehicle known to be in good working order Please refer to section 3 Performing a measurement 4 3 4 Full measurement To test the full measurement function of the AVL DiTEST HV Safety 2000 proceed as fo...

Page 43: ...ease refer to section 3 Performing a measurement 4 3 8 Capacity measurement A test of the capacity measurement of the AVL DiTEST HV Safety 2000 can be carried out as follows Measure a known capacitance Please refer to section 3 Performing a measurement 4 4 Service screen Click on Service Maintenance HV SAFETY Service screen The service screen shows Communication status Firmware version Firmware ch...

Page 44: ...Troubleshooting AVL DiTEST HV Safety 2000 4 4 User manual ...

Page 45: ...f death from electrical voltage If the AVL DiTEST HV Safety 2000 USB cable or test cables with probe tips are damaged these must not be used until approval is given by a qualified expert 5 2 Cleaning the product Danger of death from electrical voltage Always disconnect the test cables and USB cable before you clean the AVL DiTEST HV Safety 2000 Clean the AVL DiTEST HV Safety 2000 using a dry cloth...

Page 46: ...Maintenance and care AVL DiTEST HV Safety 2000 5 2 User manual ...

Page 47: ...enetration of moisture e g water oil acids etc External intervention e g repairs carried out by non authorized people Improper operation e g control of touch screen with sharp or pointed object cleaning with compressed air Improper storage care and maintenance e g cleaning the device with solvent based cleaners 6 2 Exchange or loaned devices The agreements with your supplier apply For the executio...

Page 48: ...Warranty AVL DiTEST HV Safety 2000 6 2 User manual ...

Page 49: ...nt of DC voltages Any outlets installed in the vehicle must not be measured Measurements with the AVL DiTEST HV Safety 2000 on electric vehicles may only be carried out if no charging cable is connected to the vehicle Danger of death from electrical voltage Overvoltage categories CAT II 600V CAT III 300V The AVL DiTEST HV Safety 2000 fulfils impulse voltage values as per the overvoltage category C...

Page 50: ...eneral measuring adapters probe tips test clips please note that these are suitable and approved for measuring and test voltage until 1000 V and correspond to the norm EN 61010 31 Danger of death from electrical voltage in vehicles with high voltage systems During measurements in high voltage environment the AVL DiTEST HV Safety 2000 may only be used if the voltage source is non grounded DANGER DA...

Page 51: ...0 m 20 to 55 C at max 20 C 10 to 80 No condensation Electrical protection Certified according the following regulations DIN EN 61010 1 IEC 1010 1 VDE 0411 1 UL 201 GARAGE EQUIPMENT CAN CSA 22 2 Nr 61010 1 04 Protection class II Index of protection IP 44 housing Pollution degree II Overvoltage category CAT I 1000V CAT II 600V CAT III 300V Supply from USB interface Nominal voltage Current consumptio...

Page 52: ...olution Tolerances 20 to 20 V 0 01 V 0 5 v M 1 5 digits 100 to 100 V 0 1 V 1 0 v M 1 5 digits 1 000 to 1 000 V 0 5 V 1 5 v M 1 5 digits 1 of the measured value 7 3 2 SAE J1766 insulation measurement Danger of death from electrical voltage Overvoltage categories CAT II 600V CAT III 300V The AVL DiTEST HV Safety 2000 fulfils impulse voltage values as per the overvoltage category CAT II 600V CAT III ...

Page 53: ... 10 kΩ 1 5 v M 1 10 100MΩ 10 kΩ 1 5 v M 1 0 1 0 5 GΩ 10 kΩ 3 v M 1 0 5 1 GΩ 10 kΩ 5 v M 1 Test voltage 250 V to 1 000 V adjustable in 16 increments Nominal test current 1 mA 1 of the measured value 7 3 4 Equipotential bonding check Danger of death from electrical voltage Overvoltage categories CAT II 600V CAT III 300V The AVL DiTEST HV Safety 2000 fulfils impulse voltage values as per the overvolt...

Page 54: ... 1 v M 50 mΩ 0 Ω to 1 kΩ 1 Ω 1 v M 1 Ω 0 Ω to 10 kΩ 10 Ω 1 v M 10 Ω 0 Ω to 100 kΩ 100 Ω 1 5 v M 100 Ω 0 Ω to 1 MΩ 1 kΩ 2 v M 1 kΩ 0 Ω to 10 MΩ 10 kΩ 2 v M 10 kΩ 2 The accuracy in the measurement range of 10 Ω is only valid after a zero adjustment 7 3 6 Diode test Danger of death from electrical voltage Overvoltage categories CAT II 600V CAT III 300V The AVL DiTEST HV Safety 2000 fulfils impulse vo...

Page 55: ... connected directly to the mains are not permitted For this reason use the AVL DiTEST HV Safety 2000 only for measurements on the vehicle Capacity measurement Range Resolution Tolerances 300nF 1nF 4 5 v M 1 1nF 3µF 10nF 4 5 v M 1 10nF 30µF 100nF 4 5 v M 1 0 1µF 300µF 1µF 4 5 v M 1 1µF 1 of the measured value 7 4 Disposal Disposal This product by AVL DiTEST is a high quality electrical and electron...

Page 56: ...Technical data AVL DiTEST HV Safety 2000 7 8 User manual ...

Page 57: ...4 2 Functions 1 1 General 1 1 General description 1 1 Hardware 2 1 HV insulation measurement 3 8 IMPORTANT SAFETY INSTRUCTIONS I Insulation monitor check 3 18 Maintenance and care 5 1 Metrology specifications 7 4 New devices 6 1 Operating data 7 3 Operation of PC programs 1 3 Overview 1 4 Performing a measurement 3 1 Probe tips 1 7 Resistance measurement 3 12 SAE J1766 measurement 3 20 Safety inst...

Page 58: ...Index AVL DiTEST HV Safety 2000 8 2 User manual ...

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