AVL DITEST IRP 120 User manual

USER MANUAL
IRP 120 / DCIR-PROBE
INTERNAL RESISTANCE PROBE
DIRECT CURRENT INTERNAL RESISTANCE PROBE
ID number:
AT7949EN
Revision:
02
Version:
05/22
Data subject to change.
All data valid at the time
of printing.
PASSION INNOVATES FUTURE

AVL DiTEST GmbH
Alte Poststraße 156
A-8020 Graz, AUSTRIA
Tel: [phone]
Fax: [phone]
[email protected]
www.avlditest.com
Copyright © 2022 AVL DiTEST GMBH. All rights reserved.
The contents of this publication, in 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 or for any damage that may arise as a result.

IRP 120
Table of Contents
1General .............................................................................................. 3
1.1 Intended Use ........................................................................................................................ 3
1.2 Target Group ........................................................................................................................ 3
1.3 Expert Review ........................................................................................................................ 3
2Safety................................................................................................. 4
2.1 Safety Instructions and Warning Signs .................................................................................... 4
2.2 IMPORTANT SAFETY INSTRUCTIONS................................................................................. 6
2.3 Safety Concept ........................................................................................................................ 7
3Scope of Supply................................................................................ 9
4Assembly......................................................................................... 10
4.1 Overview ...................................................................................................................... 10
4.2 LEDs ...................................................................................................................... 11
4.3 Current Clamp Cable.............................................................................................................. 12
4.4 Test probe cables................................................................................................................... 13
5Commissioning............................................................................... 15
5.1 Hardware ...................................................................................................................... 15
5.2 Software ...................................................................................................................... 15
5.2.1 Software Installation............................................................................................................ 15
5.2.2 Software Update.................................................................................................................. 16
6Working with the IRP 120............................................................... 17
6.1 Starting the IRP 120............................................................................................................... 17
6.2 Self-Test ...................................................................................................................... 19
6.3 Module Internal Resistance Measurement............................................................................. 22
6.3.1 Module Internal Resistance with One Module..................................................................... 24
6.3.2 Module Internal Resistance with Three Module.................................................................. 29
6.4 Measuring Contact Resistance (+)......................................................................................... 34
6.4.1 Contact Resistance (+) with One Module............................................................................ 36
6.4.2 Contact Resistance (+) with Three Modules ....................................................................... 40
6.5 Measuring Contact Resistance (-).......................................................................................... 44
6.5.1 Contact Resistance (-) with One Module............................................................................. 46
6.5.2 Contact Resistance (-) with Three Modules........................................................................ 50
6.6 Displaying Device Data .......................................................................................................... 54
7Troubleshooting.............................................................................. 56
7.1 Introduction ...................................................................................................................... 56
7.2 Error Messages...................................................................................................................... 56
8Maintenance and Care.................................................................... 57
8.1 Visual Check ...................................................................................................................... 57
8.2 Cleaning the Device ............................................................................................................... 57
9Warranty.......................................................................................... 58
9.1 New Devices ...................................................................................................................... 58
9.2 Replacement or Loaned Devices........................................................................................... 58
9.3 In the Event of Damage.......................................................................................................... 58
10 Technical Data ................................................................................ 59
10.1 CAT Overvoltage Categories ................................................................................................. 59
10.2 Operating Data ...................................................................................................................... 60
10.3 Measuring Technology........................................................................................................... 62
10.3.1 Resistance and contact resistance measurement .............................................................. 62

IRP 120
11 Index ............................................................................................... 62

IRP 120
General
User Manual
3
1 General
This documentation describes the INTERNAL RESISTANCE PROBE 120.
Follow all safety instructions in this manual.
This document is an integral part of the equipment. Keep it throughout the lifetime of the system
and pass it on to any subsequent owners or users.
IRP 120 is technically identical to the DCIR-Probe (DIRECT CURRENT INTERNAL RESISTANCE
PROBE). The only difference is in the inscription appearance (front plate and type plate) and in the
design of the user interface.
1.1 Intended Use
INTERNAL RESISTANCE PROBE, referred to in the following as IRP 120, is used to measure the
internal resistance of a battery module and the resistance between modules (busbar) of an electric
vehicle (traction) battery.
Any use beyond its intended use as well as non-compliance with the mandatory requirements and
safety measures will void the warranty and any associated liability.
1.2 Target Group
The IRP 120 is intended for testing organizations, vehicle repair/service shops or similar
establishments.
It is intended for professionally trained users only.
Comply with the regulations applicable in your country.
1.3 Expert Review
Since the measuring results of this product depend not only on the proper functioning of the
product itself, but also on a number of other boundary conditions, it is essential that the results
provided by the product be reviewed by an expert (validity check) before any further measures
based on these measuring results are made.

Safety
IRP 120
4
User Manual
2 Safety
This manual contains important warnings and safety instructions that require attention by the user.
Non-compliance with these warnings may result in death or serious injury.
Always follow the safety instructions on the screen.
2.1 Safety Instructions and Warning Signs
The following safety instructions and additional safety symbols are used in this documentation:
DANGER
DANGER indicates a dangerous situation which, if not avoided, leads to death or serious injury.
WARNING
WARNING indicates a dangerous situation which, if not avoided, can lead to death or serious
injury.
CAUTION
CAUTION indicates a dangerous situation which, if not avoided, can lead to slight or moderate
injury.
Additional safety symbols
Failure to comply with the following instructions can result in life-threatening injuries and damage to
property.
Danger due to high voltage
Explosion hazard
Danger due to hot parts

IRP 120
Safety
User Manual
5
Notes:
Note
This text refers to situations or operating errors that can lead to damage to property or data loss.
Information
This text refers to important information or instructions. Not following these instructions will
significantly prevent or hinder the successful execution of the actions described in this
documentation.

IRP 120
Safety
User Manual
6
2.2 IMPORTANT SAFETY INSTRUCTIONS
When using the product, a professional must ensure that the test object or test system cannot enter
operating modes that could cause personal injury or material damage.
1. Read all instructions.
2. Do not use the device if it is damaged. Do not use it with damaged cables. Wait until a
qualified service technician has inspected the device and/or cables.
3. Do not let the power supply and measuring cables hang over the edge of the table or
bench. Do not let them come into contact with hot parts or moving fan blades.
4. Always unplug the device when not in use. Never grab and pull on the cable when
unplugging it from the electrical outlet. Grab and pull on the plug to unplug it.
5. Let the device cool down completely before putting it away. Place the hoses loosely around
the device for storage.
6. To reduce the risk of fire, do not operate the device near open containers with flammable
liquids (gasoline).
7. Ensure adequate ventilation when working on combustion engines.
8. Keep hair, loose clothing, fingers and all body parts away from moving parts.
9. To reduce the risk of electric shock, avoid using the device on wet surfaces or exposing it
to rain.
10. Only operate the device as described in this manual. Only use accessories recommended
by the manufacturer.
11. Wear safety goggles at all times.
Everyday glasses only have shock-resistant lenses, they are not safety glasses.
KEEP THESE INSTRUCTIONS IN A SAFE PLACE

IRP 120
Safety
User Manual
7
2.3 Safety Concept
Risk of death from electric voltage on vehicles equipped with high-voltage systems
The HV battery and the components connected to it are connected to a high-voltage supply, which
can cause fatal injury.
Make sure that no one comes in contact with the HV battery, the connecting cables of the HV
battery or any other live parts.
The battery to be tested should be removed from the vehicle.
If the measurements are carried out on a battery that is open but still installed in the vehicle, the
vehicle must be deactivated and secured.
Risk of death from electric voltage on vehicles equipped with high-voltage systems
Please note that only appropriately trained and authorized personnel are allowed to carry out work
on high-voltage vehicles, particularly disassembly work.
Risk of death from electric voltage on vehicles equipped with high-voltage systems
For live-line work, specific safety and vocational training conditions apply.
Make sure to comply with these conditions in all situations.
Risk of death from electric voltage on vehicles equipped with high-voltage systems
Make sure that all necessary safety precautions have been taken before starting the measurement.
Check that the HV insulating gloves are suitable before using them.
Risk of death from electric voltage on vehicles equipped with high-voltage systems
Only use measuring equipment provided by AVL DiTEST.
If using general measuring adapters (test probes, measuring clamps, etc.), make sure that they are
suitable and approved for measuring and test voltages up to 1000 V and meet the EN 61010-31
standard.
Only use the device as specified in the description. The protection provided may otherwise be
compromised.
DANGER
DANGER
DANGER
DANGER
DANGER
DANGER

Safety
IRP 120
8
User Manual
v
WARNING
Risk of death due to electric voltage
Setting and maintenance work on open devices with live parts may only be performed by
specialists who are trained in this area and who are aware of the associated dangers.
v
WARNING
Risk of death due to electric voltage
The product may only be repaired by the supplier plant or by trained specialists.
Note
The device may only be operated with accessories and consumables supplied by AVL DiTEST or
approved by AVL DiTEST.

IRP 120
Scope of Supply
User Manual
9
3 Scope of Supply
Standard scope of supply:
Part
ID number
IRP 120
BO7970
Current clamp cable, red
BV8320
Current clamp cable, black
BV8321
Test probe cables
BV8319
Test probe, red
EU8005
Test probe, black
EU8006
User Manual
AT7949D
Spare parts:
Part
ID number
Current clamp cable, red
BV8320
Current clamp cable, black
BV8321
Test probe cables
BV8319
Test probe, red
EU8005
Test probe, black
EU8006
Rubber base
MR7459

IRP 120
Assembly
User Manual
10
4 Assembly
4.1 Overview
The following illustration shows the configuration of the IRP 120:
Fig. 1
(1) IRP 120 measuring module
(2) Air vents
(3) LEDs
(4) USB cable, connection to PC
(5) Air vents
(6) Red connection, positive current clamp
(7) Blue connection, test probes
(8) Black connection, negative current clamp
v
5
1
2
3
8
4
6
7

IRP 120
Assembly
User Manual
11
4.2 LEDs
Power LED
LED
Status
Sensor
No light
No power supplied to IRP 120.
No connection to tester.
Blue, continuously lit
IRP 120 is ready for operation.
Blue, flashing
IRP 120 is starting.
(Bootload procedure)
Status LED
LED
Status
Sensor
No light
No power supplied to IRP 120.
No connection to tester.
Green, continuously lit
IRP 120 is ready for operation.
Green, flashing quickly
Measurement is running.
Red, flashing quickly
Error,
e.g. the checksum of the installed firmware is wrong.

Assembly
IRP 120
12
User Manual
4.3 Current Clamp Cable
Risk of death due to electric voltage
The IRP 120 complies with the surge voltage values of the surge voltage category CAT-II 600 V /
CAT-III 300 V.
Do not conduct measurements on circuits connected directly to the mains.
Use the IRP 120 only for measurements at the battery.
The 1.8 m measuring cables are connected to the IRP 120.
Fig. 2
Cables
DANGER
Kelvin clamps
Plugs

IRP 120
Assembly
User Manual
13
4.4 Test probe cables
Risk of death due to electric voltage
The IRP 120 complies with the surge voltage values of the surge voltage category CAT-II 600 V /
CAT-III 300 V.
Do not conduct measurements on circuits connected directly to the mains.
Use the IRP 120 only for measurements at the battery.
The 1.8 m measuring cables are connected to the IRP 120.
Fig. 3
DANGER
Black
measuring
probe, negative
Button
Red measuring
probe, positive
Plugs

Assembly
IRP 120
14
User Manual
Probe Tips
Removable protective caps can be placed on the probe tips of the test probe cables.
Risk of death due to electric voltage
The IRP 120 complies with the surge voltage values of the surge voltage category CAT-II 600 V /
CAT-III 300 V.
Do not conduct measurements on circuits connected directly to the mains.
Use the IRP 120 only for measurements at the battery.
Risk of death due to electric voltage
Only use measuring equipment provided by AVL DiTEST.
If using general measuring adapters (test probes, measuring clamps, etc.), make sure that they are
suitable and approved for measuring and test voltages up to 1000 V and meet the EN 61010-31
standard.
Fig. 4
DANGER
DANGER
Protective cap
Probe tips
Accidental contact protection
Button (only on red test adapter)
Test adapter
Measuring cable

IRP 120
Commissioning
User Manual
15
5 Commissioning
5.1 Hardware
1. Connect the IRP 120 USB plug to a free USB port on the PC; see Fig. 5.
Fig. 5
5.2 Software
5.2.1 Software Installation
AVL DiTEST DSS Manager must be installed in order to use the IRP application. If AVL DiTEST
DSS Manager is already installed, the IRP application can also be installed.
If AVL DiTEST DSS Manager is not yet installed, it can be installed together with the IRP
application in a single package.
The installer is available at the link shown below:
1. Navigate to https://ext.avlditest.com/customer/SitePages/SoftwareDownload.aspx
2. Log in.
3. Click on DOWNLOAD SOFTWARE and then International.

Commissioning
IRP 120
16
User Manual
Fig. 6
4. Navigate to the IRP download area.
If AVL DITEST DSS Manager is installed, install Install.IRPApplication.x.x.x.x.exe.
If AVL DITEST DSS Manager is not installed, install
Install.DSSManager+IRPApplication.x.x.x.x.exe
5.2.2 Software Update
Updating the operating software used in the device takes place automatically via the PC. Make
sure that the latest version of the operating software is installed on the PC.

IRP 120
Working with the IRP 120
User Manual
17
6 Working with the IRP 120
6.1 Starting the IRP 120
Start the software by clicking Start│Programs│DiTEST│DSS.
Click Diagnostics│IRP.
Fig. 7

Working with the IRP 120
IRP 120
18
User Manual
A start screen appears.
Fig. 8