AVL DITEST HV SAFETY 2000 User manual

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

AVL DiTEST GmbH
Alte Poststrasse 156
A-8020 Graz / AUSTRIA
Tel.: [phone]
Fax: [phone]
[email protected]
www.avlditest.com
Copyright © 2018 AVL DiTEST GMBH, all 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.

AVL DiTEST HV Safety 2000
IMPORTANT SAFETY INSTRUCTIONS
User manual
I
IMPORTANT SAFETY INSTRUCTIONS
Read all instructions –SAVE THESE INSTRUCTIONS
Read all instructions.
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 service person.
Do not let the supply lead and the measuring leads hang over the edge of the
table, bench, or counter or come in contact with hot manifolds or moving fan
blades.
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.
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, loose clothing, fingers, and all parts of body away from moving parts.
To reduce the risk of electric shock, do not use on wet surface or expose to rain.
Use only as described in this manual. Use only manufacturers recommended
attachments.
ALWAYS WEAR SAFETY GLASSES.
Everyday eyeglasses only have impact resistant lenses, they are not safety
glasses.

IMPORTANT SAFETY INSTRUCTIONS
AVL DiTEST HV Safety 2000
User manual
II
Warning and safety instructions
This equipment manual contains important warnings and safety information
which must be observed by the user.
The product is only intended for a very specific application described in the
equipment manual. Furthermore, the most important prerequisites and safety
measures required for the use and operation of the product are explained to
ensure smooth operation.
We do not accept any warranty and liability for applications other than the
application described and without observing the required preconditions and safety
measures.
The product may only be used and operated by personnel that due to its
professional qualification is able to observe the 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 check) by an expert
prior to implementing further measures based on the generated measured value.
Adjustments and maintenance of live, opened devices may only be carried out by
qualified personnel trained for that purpose and that is aware of the risks involved.
The product may only be repaired at the supplying factory or by the qualified
personnel trained for that purpose.
When using the product, a specialist must ensure that neither the test object nor
the test facility can operate in such a manner that it might damage property or put
personnel at risk.

AVL DiTEST HV Safety 2000
Summarised safety notes
User manual
III
Summarised safety notes
Danger of death from electrical voltage in vehicles with high-voltage systems
The HV battery and the parts connected to it operate at a potentially lethal high voltage.
Make sure that nobody touches the terminals of the HV battery, the connection cables of the HV
battery and other parts under high voltage.
Danger of electric shock on the ignition system
The ignition system is under life-threatening high voltage!
Do not touch the ignition system while 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 space should be adequately ventilated!
Risk of burns due to hot components
Perform measurements at normal engine operating temperature or follow the respective test
specification!
Do not touch any hot components such as engine, engine mountings and the entire exhaust
system!
If necessary, use cooling fans!
DANGER
WARNING
WARNING
WARNING
WARNING

Summarised safety notes
AVL DiTEST HV Safety 2000
IV
User manual
Risk of injury due to rotating parts
Perform any work in the engine compartment while engine and ignition are turned off!
Do not touch any rotating parts, such as, assemblies of electric generator, radiator fan and their
drives (e.g. V belt)!
With running engine ensure a safe installation of the measuring cables!
Risk of injury due to unsecured vehicle
Apply the hand brake or place the selector lever to P (automatic transmission)!
Secure vehicle adequately against rolling!
Explosion hazard due to pyrotechnic installation and restraint system
Test and installation work should only be carried out by trained personnel!
Under no circumstances should the igniter be tested with the multimeter!
System verification 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 sparks, open fire and temperatures above 100°C!
Do not transport airbag unit in the passenger compartment!
Do not bring airbag unit in contact with oil, grease and cleaning agents!
Airbag unit that dropped more than 0.5m has to be replaced!
Dispose of untriggered airbag units!
Do not open or repair airbag unit!
Observe the applicable manufacturer's specifications when holding the cutoff speed of diesel
engines!
Always switch off the ignition first before connecting and disconnecting the OBD plugs or the
different AVL vehicle adapters!
WARNING
NOTICE
WARNING
WARNING
NOTICE

AVL DiTEST HV Safety 2000
Safety notes
User manual
V
Safety notes
Danger of death from electrical voltage
The AVL DiTEST HV Safety 2000 is not suitable for measurements on the mains!
The AVL DiTEST HV Safety 2000 is only suitable for measuring 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 in vehicles with high-voltage systems
Please note that only trained and authorised staff is allowed to carry out work, in particular
dismantling work, on high voltage vehicles.
Danger of death from electrical voltage in vehicles with high-voltage systems
Life-threatening high voltage is 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 situation!
Danger of death from electrical voltage in vehicles with high-voltage systems
Please make sure that all required safety precautions are taken before you start measuring!
Danger of death from electrical voltage in vehicles with high-voltage systems
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 voltage until 1000V and correspond to the norm EN
61010-31!
DANGER
DANGER
DANGER
DANGER
DANGER
DANGER

Safety notes
AVL DiTEST HV Safety 2000
VI
User manual
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 of death from electrical voltage in vehicles with high-voltage systems
During high voltage insulation measurement, you must make sure not to touch test adapter tips
which are not insulated! During measurement, a test high voltage (250V, 500V to 1000V) is
generated with a test current of up to 2mA flowing through the connected test object. If you touch
not insulated test adapter tips, you can feel the electric shock considerably. However, the electric
current 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 battery) from the HV vehicle electrical
system. Secure the measured object against switching back on! After disconnecting the HV energy
store, you must wait at least 2 minutes for all capacitors (e.g.: link circuit capacitors) to discharge.
Before every high-voltage insulation measurement, do a voltage measurement to make sure no
voltage is applied to the measured object! (Measurement, as close to the work location as possible)
Make sure neighboring live parts are covered and secured!
SAVE THESE INSTRUCTIONS
DANGER
DANGER
DANGER

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
1General............................................................................................. 1-1
1.1 General description.......................................................................................................... 1-1
1.2 Safety instructions............................................................................................................1-2
1.3 Typographical conventions.............................................................................................. 1-2
1.4 Operation of PC programs............................................................................................... 1-3
1.5 Design..............................................................................................................................1-4
1.5.1 Overview........................................................................................................1-4
1.5.2 Top side......................................................................................................... 1-5
1.5.3 Test adapters.................................................................................................1-6
1.5.4 Probe tips.......................................................................................................1-7
2Commissioning............................................................................... 2-1
2.1 Hardware......................................................................................................................... 2-1
2.2 Software.......................................................................................................................... 2-1
2.2.1 Data entry and settings..................................................................................2-2
2.2.1.1 Settings for HV Safety....................................................................................2-2
3Performing 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
3.10 SAE J1766 measurement..............................................................................................3-18
3.11 Full measurement.......................................................................................................... 3-20
4Troubleshooting.............................................................................. 4-1
4.1 Introduction......................................................................................................................4-1
4.2 Error messages................................................................................................................4-1
4.3 Function test ....................................................................................................................4-2
4.3.1 DC Voltage measurement ............................................................................. 4-2
4.3.2 HV insulation measurement...........................................................................4-2
4.3.3 SAE J1766 measurement..............................................................................4-2
4.3.4 Full measurement..........................................................................................4-2
4.3.5 Resistance measurement..............................................................................4-2

Table of contents
AVL DiTEST HV Safety 2000
VIII
User manual
4.3.6 Diode test.......................................................................................................4-3
4.3.7 Equipotential bonding check..........................................................................4-3
4.3.8 Capacity measurment....................................................................................4-3
4.4 Service screen................................................................................................................. 4-3
5Maintenance and care..................................................................... 5-1
5.1 Visual check..................................................................................................................... 5-1
5.2 Cleaning the product........................................................................................................ 5-1
6Warranty........................................................................................... 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
7Technical 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
7.3.6 Diode test.......................................................................................................7-6
7.3.7 Capacity measurement..................................................................................7-7
8Index ............................................................................................... 8-1

AVL DiTEST HV Safety 2000
General
User manual
1-1
1 General
1.1 General description
The AVL DiTEST HV Safety 2000 is used in conjunction with AVL DSS to conduct measurements
on modern vehicles equipped with a high-voltage system.
Functions:
Initialisation/self-test
DC voltage measurement (absence of voltage)
Insulation resistance measurement
(calculation of insulation resistance by current and voltage measurement)
Insulation resistance measurement to SAE J1766
(measurement under load with parallel resistance)
Full measurement
(combines the 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
transient current and voltage after the high-voltage insulation resistance measurement
High-voltage safety circuit (automatic switch-off)
Function indicator with 2 LEDs
Compatibility between AVL DiTEST HV Safety 2000 and AVL DSS
Power supply by USB interface, 5 V / 500 mA (500 mA: maximum value)
Interface: USB 2.0
Galvanic isolation from USB interface

General
AVL DiTEST HV Safety 2000
1-2
User manual
1.2 Safety instructions
This documentation contains important warnings and safety instructions which have to be observed
by the user. Only through compliance with these requirements and safety measures it is possible to
ensure correct and safe operation.
Please note the safety instructions on the screen.
1.3 Typographical conventions
Safety instructions:
Indicates an extremely 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 important information or instructions. Failure to comply with these instructions
prevents or significantly hampers a successful finalization of the operations described in this
documentation.
WARNING
CAUTION
DANGER
NOTICE
Information

AVL DiTEST HV Safety 2000
General
User manual
1-3
Standard text formats:
bold
Important text/text passages, parameter
italic
On screen dialogs and messages
CAPITAL LETTERS
Device designation and operating conditions
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 administrator.

General
AVL DiTEST HV Safety 2000
1-4
User manual
1.5 Design
1.5.1 Overview
The AVL DiTEST HV Safety 2000 comprises the following components
(1) AVL DiTEST HV Safety test module
(2) LEDs, blue and red/green
(3) Black protective cap to 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. 1-1
11
10
12
1
2
9
3
4
5
6
7
8

AVL DiTEST HV Safety 2000
General
User manual
1-5
1.5.2 Top side
There are two LEDs (1) and (2) on the top:
LED
LED colour
LED state
Meaning
Blue
Lit
Operation normal
Slow flashing
Error during normal 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

General
AVL DiTEST HV Safety 2000
1-6
User manual
1.5.3 Test adapters
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 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
contact
Button (on the red test adapter
only)
Test adapter
Test cable
DANGER

AVL DiTEST HV Safety 2000
General
User manual
1-7
1.5.4 Probe tips
Probe tips with removable protective caps can be attached to the test adapters.
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 600 V / CAT-III 300 V.
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.
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 voltage until 1000 V and correspond to the norm
EN 61010-31!
Fig. 1-4
Protective cap
Probe tips
Protection against accidental
contact
Button (on the red test adapter
only)
Test adapter
Test cable
DANGER
DANGER

General
AVL DiTEST HV Safety 2000
1-8
User manual

AVL DiTEST HV Safety 2000
Commissioning
User manual
2-1
2 Commissioning
Please also refer to the AVL DSS user manual and the AVL DSS quick-reference guide.
2.1 Hardware
1. Connect a USB cable between the USB socket on the AVL DiTEST HV Safety 2000 and a
spare USB socket on the AVL DSS PC, see Fig. 2-1.
Fig. 2-1
2. With use of an AVL MDS trolley:
Place the AVL DiTEST HV Safety 2000 somewhere suitable on the tray of the AVL MDS
trolley.
2.2 Software
Please note that the AVL DiTEST HV Safety 2000 works 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 section 2 “AVL DSS update”of the
AVL DSS brief instruction.
3. Copy the licence file to the dongle.
Proceed as described in section 3 “Import of licence file to dongle”of the
AVL DSS brief instruction.
The AVL DSS brief instruction (ID no.: AT7260) comes with the AVL DSS DVD.
NOTICE
USB connector
USB socket

Commissioning
AVL DiTEST HV Safety 2000
2-2
User manual
2.2.1 Data entry and settings
Please refer to section 3.1.2.1 “Settings”of the AVL DSS user manual.
Please also refer to section 3.1.2.2 “Log file”. This section provides a detailed description of how to
manage the logged settings and operating steps.
2.2.1.1 Settings for HV Safety
Click on ExtrasSettingsApplicationsHV Safety
Results
By enabling "Automatic save", the measurement results are saved automatically.
Audible feedback
By enabling "On" an acoustic feedback operates during measuring.
Conductor
If the "Enable 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 box) appears, at the
beginning of each measurement, to enter the vehicle information.
Activation of special measurements
By activating the current records, the special measurement functions (insulation monitor check,
SAEJ1766 measurement and overall measurement) will appear in the measurement function
selection on the home screen of the HV Safety application (see Figure 3-1).