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