AVL DITEST MCS 120 User manual

USER MANUAL
AVL DITEST MCS 120
MODULE CONDITIONING SYSTEM
Ident number:
AT7953E
Revision:
02
Issue:
2020-04
Software version:
Data may change without notice.
Alldatavalidattimeofprinting.
PASSION INNOVATES FUTURE

AVL DiTEST GmbH
Alte Poststrasse 156
8020 Graz
AUSTRIA
Tel: [phone]
Fax: [phone]
[email protected]
www.avlditest.com
Copyright © 2020 AVL DiTEST GMBH, all rights reserved.
The content of this publication may not be reproduced in any way or forwarded to third
parties, either in part or in full, without the prior written consent of AVL DiTEST. This
publication was created with due care such that AVL DiTEST is not liable for any remaining
errors or omissions or for any damages arising therefrom.

AVL DiTEST MCS 120
Warning and Safety Notes
User Manual
I
Warning and Safety Notes
This user manual contains important warning and safety notices that must be
observed by the user.
The product is intended only for the highly specific use described in the user
manual. The most important prerequisites and safety measures for the use and
operation of the product are also described to ensure faultless operation.
No warranty can be given and no liability is assumed for applications beyond the
described use, irrespective of observance of the necessary prerequisites and
safety measures.
The product may only be used and operated by personnel who, based on their
qualifications, are capable of adhering to the necessary safety measures during
use and operation. Only accessories and consumables supplied by AVL DiTEST
or approved by AVL DiTEST may be used. The measurement results obtained
from the product in question depend not only on correct functioning of the product,
but also on a series of general conditions. The results delivered by the product
must therefore be evaluated by a specialist (e.g. plausibility check) before further
measures are taken on the basis of a delivered measurement.
Settings and maintenance work on open devices while still live may only be
performed by trained specialists who are aware of the associated danger.
The product may only be repaired in the factory of origin or by specialists
specifically trained to perform such repair.
When using the product, it must be ensured by a specialist that the test object or
test system is not brought into any operational state that could result in damage to
goods or endangerment of people.

Warning and Safety Notes
AVL DiTEST MCS 120
II
User Manual

AVL DiTEST MCS 120
Special Safety
User Manual
III
General Safety
Danger to life by electric potential on vehicles with high voltage systems
Deadly high voltages are present on the HV energy store (HV battery) and on
parts connected to it!
Make sure no-one can come into contact with the connections on the HV battery,
connecting cables of the HV battery or other parts under high voltage!
The battery to be tested should be removed from the vehicle.
If the measurements are made on an open but still installed in the vehicle battery,
the vehicle must be disabled and secured.
Danger to life by electric potential on vehicles with high voltage systems
Please note that work, in particular dismantling, on high-voltage vehicles may only
be carried out by suitably trained and authorized personnel.
Danger to life by electric potential on vehicles with high voltage systems
For work under tension special safety and training conditions apply!
In every situation make sure that these are observed!
Danger to life by electric potential on vehicles with high voltage systems
Make sure that all necessary safety precautions have been taken before you start
measuring.
Check the HV insulation gloves for suitability before using them!
WARNING
When connecting the cell module, make sure the IR temperature sensor is
not covered and ensure direct visibility between the sensor and the module.
DANGER
DANGER
DANGER
DANGER

Special Safety
AVL DiTEST MCS 120
IV
User Manual

AVL DiTEST MCS 120
IMPORTANT SAFETY INSTRUCTIONS
User Manual
V
IMPORTANT SAFETY INSTRUCTIONS
1. Read all instructions.
2. Care must be taken as burns can occur from touching hot parts.
3. Do not operate equipment with a damaged cord or if the
equipment has been dropped or damaged - until it has been
examined by a qualified serviceman.
4. Do not let cord hang over edge of table, bench or counter or
come in contact with hot manifolds or moving fan blades.
5. If an extension cord is necessary, a cord with a current rating
equal to or more than that of the equipment should be used.
Cords rated for less current than the equipment may overheat.
Care should be taken to arrange the cord so that it will not be
tripped over or pulled.
6. Always unplug equipment from electrical outlet when not in use.
Never use the cord to pull the plug from the outlet. Grasp plug
and pull to disconnect.
7. Let equipment cool completely before putting away. Loop cord
loosely around equipment when storing.
8. To reduce the risk of fire, do not operate equipment in the vicinity
of open containers of flammable liquids (gasoline).
9. Adequate ventilation should be provided when working on
operating internal combustion engines.
10. Keep hair, loose clothing, fingers, and all parts of body away
from moving parts.
11. To reduce the risk of electric shock, do not use on wet surfaces
or expose to rain.
12. Use only as described in the manual. Use only manufacturer´s
recommended accessories.
13. ALWAYS WEAR SAFETY GLASSES. Everyday eyeglasses only
have impact resistant lenses, they are NOT safety glasses.
SAVE THESE INSTRUCTIONS

IMPORTANT SAFETY INSTRUCTIONS
AVL DiTEST MCS 120
VI
User Manual

AVL DiTEST MCS 120
Content
User Manual
VII
Content
Warning and Safety Notes ........................................................................... I
General Safety ............................................................................................ III
IMPORTANT SAFETY INSTRUCTIONS.......................................................V
1General .............................................................................................. 1
1.1 General Notes..................................................................................................................... 1
1.2 EC Declaration of Conformity/CE mark.............................................................................. 2
1.3 Certificate of Calibration...................................................................................................... 4
1.4 Designated Use .................................................................................................................. 6
1.5 Field of application.............................................................................................................. 6
2Components...................................................................................... 7
2.1 Cable sets......................................................................................................................... 16
2.1.1 USB-cable (USB 2.0 A auf USB 2.0 B Rugged) EX7069................................................. 16
2.1.2 Cable Set plus minus, X590 ............................................................................................. 16
2.1.3 Cable, analog module, X590 ............................................................................................ 16
2.1.4 Cable, CAN bus module ................................................................................................... 17
2.1.5 SPI-UART-Adapter ........................................................................................................... 18
3Commissioning............................................................................... 19
3.1 Installation of the DSS Software....................................................................................... 19
3.2 Firmware Update .............................................................................................................. 19
3.3 Hardware .......................................................................................................................... 20
4Performing a Measurement............................................................ 23
4.1 Start MCS 120 .................................................................................................................. 23
4.1.1 Safety test......................................................................................................................... 32
4.1.2 Self-test............................................................................................................................. 35
4.1.3 Deviceinfo ......................................................................................................................... 37
4.1.4 Viewing all reports............................................................................................................. 39
4.1.5 Result report directory....................................................................................................... 41
4.1.6 Entering a list of operator names...................................................................................... 42
4.1.7 Switch off .......................................................................................................................... 42
5Troubleshooting.............................................................................. 43
6Maintenance and care..................................................................... 45
6.1 Optical check .................................................................................................................... 45
6.2 Cleaning............................................................................................................................ 45
7Scope of delivery............................................................................ 47
8Technical data................................................................................. 49
8.1 Operating data .................................................................................................................. 49
9Index ............................................................................................... 51

Content
AVL DiTEST MCS 120
VIII
User Manual

AVL DiTEST MCS 120
General
User Manual
1
1 General
1.1 General Notes
The Module Conditioning System MCS 120, here after named MCS 120, is able
to charge and discharge single cell modules of high voltage batteries from E-cars
and hybrid cars.
To guarantee an overall equal load of all cell modules on a HV-battery, the new
cell module has to be charged / discharged to meet this load of the whole battery.
The conditioned „balanced“ cell module replaces the defect cell module.
MCS 120 is technically identical to MCS (Module Conditioning System).
Differences exist only in the appearance of the imprints (front plate and type plate)
and in the design of the user interface.
The MCS 120 is designed to use in car shops which have to do HV battery repairs.
To use this device you must have a special qualification. See below.
Please follow the regulation valid to your country!
Read this operating manual and follow especially the safety hints!

General
AVL DiTEST MCS 120
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User Manual
1.2 EC Declaration of Conformity/CE mark
The manufacturer hereby declares (fig 1-1) that the MCS is in conformity with the
regulations of the following EC directives, including all the relevant modifications
2014/30/EU Council Directive on the approximation of the laws of the
Member
States relating to electromagnetic compatibility
2014/35/EU Council Directive on the approximation of the laws of the
Member
States related to electrical equipment designed for use within
certain voltage limits
2011/65/EU Directive on the restriction of the use of certain hazardous
Substances in electrical and electronic equipment
The following standard conformities are available at the MCS:
SAFETY:
EN 61010-1 Safety requirements for electrical equipment
IEC 61010-1 for measurement, control, and laboratory use –
UL 61010-1 Part 1: General requirements
CAN/CSA-C22.2 No. 61010-1-12
EN 61010-2-30 Safety requirements for electrical equipment
IEC 61010-2-30 for measurement, control, and laboratory use.
UL 61010-2-30 Particular requirements for testing and measuring circuits
CAN/CSA-C22.2 No. 61010-2-30
UL 201 Standard for Garage Equipment
UL 60950-1 Information Technology Equipment
EMV / EMC:
EN 61326-1 Electrical equipment for measurement, control and
IEC 61326-1 laboratory use –EMC requirements –Part 1: General
requirements
FCC Part-15 Subpart-B Part 15—Radio Frequency Devices Subpart B—
Unintentional Radiators
RoHS
EN 50581 Technical documentation for the assessment of
electrical and electronic products with respect to
the restriction of hazardous substances

AVL DiTEST MCS 120
General
User Manual
3
EC Declaration of Conformity/CE mark
Fig. 1-1 EC Declaration of Conformity/CE mark

General
AVL DiTEST MCS 120
4
User Manual
1.3 Certificate of Calibration
The manufacturer hereby declares (fig 1-2) that the device delivered with this
operating manual does not require any calibration within the first 24 month after its
delivery. Subsequent calibrations should be carried out every 12 months.

AVL DiTEST MCS 120
General
User Manual
5
Module Conditioning System MCS 120
Bestellnummer: BO7971
Das Module Conditioning System MCS 120 wurde unter Einhaltung aller
Vorgaben nach der jeweils gültigen Prüfvorschrift erfolgreich getestet
und hat in einwandfreiem Zustand unser Haus verlassen.
In den ersten 24 Monaten nach der Auslieferung des Geräts ist keine
Kalibrierung erforderlich.
The Module Conditioning System MCS 120 was tested successfully
with compliance to all specified values and under the actual test
procedure and left our facilities in perfect condition.
During the first 24 month after delivery of the device, calibration is not
required.
AVL DiTEST ist nach ISO 9001 zertifiziert!
AVL DiTEST is accredited according to ISO 9001!
AVL DiTEST GmbH - Alte Poststrasse 156 - A-8020 Graz
Fig. 1-2 Certificate of initial calibration

General
AVL DiTEST MCS 120
6
User Manual
1.4 Designated Use
It’s only allowed to use the MCS 120 in that way, described in this manual.
WARNING
The Housing should only be opened by AVL DiTEST Service.
The product described has been developed, manufactured and checked according
to the relevant safety standards. If the safety instructions are observed, the start-
up is carried out as stipulated, the device is used for the intended purpose and the
recommended maintenance and care is also observed, then in normal cases there
is no danger regarding damages to property or for the health of persons
associated with the MCS 120.
1.5 Field of application
The MCS 120 is designed for charging / discharging of single cell modules of a HV
battery to a certain load level.

AVL DiTEST MCS 120
Components
User Manual
7
2 Components
Transport box closed
Fig. 2-1 Transport box closed
(1) Latch
(2) Carrying handle
(3) Latch
(4) Latch
(5) Carrying handle
(6) Latch
1 2 3
6 5 4

Components
AVL DiTEST MCS 120
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User Manual
Transport box opened, with MCS 120
Fig. 2-2 Transport box opened
(1) MCS 120
(2) Accessories
(3) Transport box, bottom part
1 2
3

AVL DiTEST MCS 120
Components
User Manual
9
Transport box opened, with MCS 120
Fig. 2-3 Transport box opened, with MCS 120
(1) MCS 120
(2) Transport box, bottom part
1
2

Components
AVL DiTEST MCS 120
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User Manual
Transport box opened, MCS 120, cell module
Fig. 2-4 Adapter und transport box open (top view).
(1) Cell module
(2) MCS
(3) Transport box, (bottom part)
1
2
3
3