KTM AVL HV SAFETY 2000 User manual

OWNER'S MANUAL 2015
AVL HV SAFETY 2000
Art. no. 3206226en

INTRODUCTION
*3206226en*
3206226en
11/2018
INTRODUCTION
Read this operating manual carefully and thoroughly before beginning work.
This operating manual was written to correspond to the latest state of this series. We reserve the right to make
changes in the interest of technical advancement without updating this operating manual at the same time.
All specifications contained herein are non-binding. KTM Sportmotorcycle GmbH specifically reserves the right
to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc.,
without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop produc-
tion of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from fig-
ures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that
does not belong to the regular scope of supply.
© 2018 KTM Sportmotorcycle GmbH, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission
of the copyright owner.
ISO 9001(12 100 6061)
KTM applies quality assurance processes that lead to the highest possible product quality as
defined in the ISO 9001 international quality management standard.
Issued by: TÜV Management Service
KTM Sportmotorcycle GmbH
Stallhofnerstraße 3
5230 Mattighofen, Austria

TABLE OF CONTENTS
2
TABLE OF CONTENTS
1 MEANS OF REPRESENTATION ...................... 3
1.1 Symbols used .................................... 3
1.2 Formats used..................................... 4
2 SAFETY ADVICE............................................ 5
2.1 Use definition –intended use.............. 5
2.2 Fire hazard........................................ 5
3 IMPORTANT NOTES...................................... 6
3.1 Handling a KTM PowerPack following
an accident ....................................... 6
3.2 Securing workplaces in the workshop ... 7
4 ZERO POTENTIAL......................................... 8
4.1 Determining that the KTM PowerPack
is at zero potential .......................... 8
4.2 Ascertaining that the discharge plug
is at zero potential .......................... 9
4.3 Ascertaining that the motor
electronics control unit is at zero
potential ...................................... 11
5 INSULATION MEASUREMENT..................... 14
5.1 Performing an
insulation measurement on the
KTM PowerPack ........................... 14
5.2 Performing an insulation
measurement on the discharge
plug ............................................ 15
5.3 Performing an insulation
measurement on the motor
electronics control unit ................. 17
5.4 Performing an insulation
measurement on the high-voltage
wiring harness .............................. 19
5.5 Performing an insulation
measurement on the stator ............ 20
6 EQUIPOTENTIAL BONDING CHECK ............. 23
6.1 Performing an equipotential
bonding check (KTM PowerPack
installed) ..................................... 23
6.2 Performing an equipotential
bonding check (KTM PowerPack
installed) ..................................... 25
INDEX ............................................................... 27

MEANS OF REPRESENTATION 1
3
1.1 Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
Identifies work requiring expert knowledge and technical understanding. In the interest of your
own safety, only have these jobs performed by correspondingly trained KTM technical person-
nel.
All work identified by this symbol requires a level 1 qualification for high-voltage systems. Only
this qualification authorizes you to perform non-electro-technical work on a vehicle or on units
with a high-voltage system.
All work identified by this symbol requires a level 2 qualification for high-voltage systems.
Only this qualification authorizes you to de-energize the electrical system and perform
electro-technical work in a de-energized state.
All work identified by this symbol requires a level 3 qualification for high-voltage systems. Only
this qualification authorizes you to perform electro-technical work under voltage.
Indicates a page reference (more information is provided on the specified page).
Indicates information with more details or tips.
Indicates the result of a testing step.
Indicates a voltage measurement.
Indicates a current measurement.
Indicates a resistance measurement.
Indicates the end of an activity including potential rework.

1 MEANS OF REPRESENTATION
4
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Indicates a proprietary name.
Name®Indicates a protected name.
Brand™ Indicates a brand available on the open market.
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which
are explained in the glossary.

SAFETY ADVICE 2
5
2.1 Use definition –intended use
Warning
Risk of injury Alternating current is not detected by the AVL DiTEST HV Safety 2000.
A component with alternating current applied is shown as having zero potential by the
AVL DiTEST HV Safety 2000.
A measurement of alternating current cannot damage the device.
–Only use the AVL DiTEST HV Safety 2000 for measuring direct current.
The AVL DiTEST HV Safety 2000 is for measuring direct currently only.
2.2 Fire hazard
Warning
Fire hazard Damaged rechargeable lithium-ion batteries (KTM PowerPacks) present a fire hazard.
Massive mechanical damage may cause an internal cell short circuit and as a consequence may cause
the battery to self-ignite.
–Contact the KTM customer service immediately if major damage to the rechargeable lithium-ion bat-
tery (KTM PowerPack) has occurred.
There is no particular fire hazard for this vehicle when the rechargeable lithium-ion battery (KTM PowerPack) is
intact.
However, should the vehicle catch fire, inform the fire brigade responsible that an electric vehicle with a
rechargeable lithium-ion battery is on fire.

3 IMPORTANT NOTES
6
3.1 Handling a KTM PowerPack following an accident
Warning
Risk of injury The housing of a damaged lithium-ion battery (KTM PowerPack) could be live.
–Contact the KTM customer service immediately if major damage to the rechargeable lithium-ion bat-
tery has occurred.
Warning
Fire hazard Damaged rechargeable lithium-ion batteries (KTM PowerPacks) present a fire hazard.
Massive mechanical damage may cause an internal cell short circuit and as a consequence may cause
the battery to self-ignite.
–Contact the KTM customer service immediately if major damage to the rechargeable lithium-ion bat-
tery (KTM PowerPack) has occurred.
Warning
Fire hazard Attempts to extinguish a fire with too little water intensify a lithium-ion battery
(KTM PowerPack) fire.
Any lithium-ion batteries (KTM PowerPacks) already on fire cannot be extinguished, but only be cooled.
–In the event of lithium-ion battery (KTM PowerPack) fires, always use very large quantities of water to
cool any cells not yet burning.
Info
The vehicle is a high-voltage electric motorcycle with a rechargeable lithium-ion battery (KTM PowerPack,
260 V).
The high-voltage components in the vehicle are marked with yellow warning labels.
The high-voltage cabling in the motor case and in the KTM PowerPack is indicated by the orange insula-
tion.
Before beginning work on the vehicle, the main switch on the right of the handlebar must be switched off.
Numerous vehicle crash tests that extend beyond the scope of the legal and consumer-protection require-
ments have demonstrated that the KTM PowerPack guarantees a high level of safety even in the event of
accidents.
Risk of electric shock:
–In the event of touching both battery terminals, if each line is touched by one hand respectively.
–In the event of touching one phase and the motor case or the frame respectively if there is a short-circuit to
the case from another phase.
Fire hazard:
–Examinations have demonstrated that the KTM PowerPack is highly fire-resistant even when exposed to fires
acting on it from outside.
Vehicle fire:
–Causes of fire are reduced to the greatest possible extent by means of analyses and the measures derived
from them during development and production.
–If a KTM PowerPack catches fire, the metallic lithium will also burn and continue burning even without a sup-
ply of ambient air.
–If large quantities of water are used, the toxic gases produced will be bound and corrosive fluids will be
diluted. While the fire will not be extinguished, it will be robbed of energy. This allows the fire to remain
under control.
Info
When working on a vehicle which has been in an accident, always wear protective clothing.

IMPORTANT NOTES 3
7
Recommended extinguishing agents:
–Depending on the location of use, large quantities of water or foam and, if available, sand or metal fire extin-
guisher.
–Internal short-circuits resulting in overheating and fire cannot be completely precluded regardless of the time
which has elapsed since the damage.
–If in doubt, a controlled battery burn-off may have to be considered.
3.2 Securing workplaces in the workshop
Nicht schalten,
es wird gearbeitet!
Ort: Datum:
Entfernen des Schildes
nur durch:
402258-01
–Safety equipment must be worn at all times when working on
the vehicle.
–The workplace for the vehicle must be clearly marked and be
equipped with safety measures.
Floor mat (70029006000)
Safety gloves (70029007000)
Inner glove liners (70029008000)
Warning tape (70029015000)
Safety helmet (70029003000)
Safety mask (70029004000)
Holder for safety mask (70029005000)
Prohibition sign (70029009000)
Warning sign (70029010000)
Warning sign (70029011000)
Warning sign (70029012000)
Prohibition sign (70029013000)
Transport system (70029020000)
Fire-resistant cabinet for hazardous goods (70029016000)

4 ZERO POTENTIAL
8
4.1 Determining that the KTM PowerPack is at zero potential
Warning
Risk of injury The measuring points could be live.
–Use personal protective clothing and comply with the safety measures.
Condition
The KTM PowerPack has been removed.
–Prepare the special tool for measurement.
AVL DITEST HV Safety 2000 (70029068000)
–Start software HV Safety.
–Select "Zero-potential".
310406-51
–Measure the voltage between the specified points.
High-voltage plug for KTM PowerPack FV pin 1–High-
voltage plug for KTM PowerPack FV pin 2
< 40 V
» If the specified value is not reached:
–Contact KTM customer service.
–Secure the KTM PowerPack in the transport and quar-
antine box, if necessary.
Transport system (70029020000)

ZERO POTENTIAL 4
9
310408-51
–Measure the voltage between the specified points.
High-voltage plug for KTM PowerPack FV pin 1–High-
voltage plug for KTM PowerPack FV pin gnd
< 40 V
» If the specified value is not reached:
–Contact KTM customer service.
–Secure the KTM PowerPack in the transport and quar-
antine box, if necessary.
Transport system (70029020000)
310407-51
–Measure the voltage between the specified points.
High-voltage plug for KTM PowerPack FV pin 2–High-
voltage plug for KTM PowerPack FV pin gnd
< 40 V
» If the specified value is not reached:
–Contact KTM customer service.
–Secure the KTM PowerPack in the transport and quar-
antine box, if necessary.
Transport system (70029020000)
4.2 Ascertaining that the discharge plug is at zero potential
Warning
Risk of injury The measuring points could be live.
–Use personal protective clothing and comply with the safety measures.
Condition
The KTM PowerPack has been removed.
–Prepare the special tool for measurement.
AVL DITEST HV Safety 2000 (70029068000)
–Start software HV Safety.
–Select "Zero-potential".

4 ZERO POTENTIAL
10
310409-51
–Measure the voltage between the specified points.
Battery discharge plug FU pin 1–Battery discharge
plug FU pin 2
< 40 V
» If the specified value is not reached:
–Discharge intermediate circuit capacitors.
310410-51
–Measure the voltage between the specified points.
Battery discharge plug FU pin 1–Measuring point
Motor case
< 40 V
» If the specified value is not reached:
–Discharge intermediate circuit capacitors.

ZERO POTENTIAL 4
11
310411-51
–Measure the voltage between the specified points.
Battery discharge plug FU pin 2–Measuring point
Motor case
< 40 V
» If the specified value is not reached:
–Discharge intermediate circuit capacitors.
4.3 Ascertaining that the motor electronics control unit is at zero potential
Warning
Risk of injury The measuring points could be live.
–Use personal protective clothing and comply with the safety measures.
Condition
The KTM PowerPack and motor have been removed.
–Prepare the special tool for measurement.
AVL DITEST HV Safety 2000 (70029068000)
–Start software HV Safety.
–Select "Zero-potential".

4 ZERO POTENTIAL
12
310412-51
–Measure the voltage between the specified points.
Measuring point HV+ –Measuring point HV−
< 40 V
» If the specified value is not reached:
–Discharge the intermediate circuit capacitors (motor
removed).
–Clean the sealing surface.
Info
Sealant on the contact surface between the motor
housing and the measurement tip can falsify
measurements.
310413-51
–Measure the voltage between the specified points.
Measuring point HV+ –Measuring point Motor case
< 40 V
» If the specified value is not reached:
–Discharge the intermediate circuit capacitors (motor
removed).

ZERO POTENTIAL 4
13
310414-51
–Measure the voltage between the specified points.
Measuring point HV− – Measuring point Motor case
< 40 V
» If the specified value is not reached:
–Discharge the intermediate circuit capacitors (motor
removed).

5 INSULATION MEASUREMENT
14
5.1 Performing an insulation measurement on the KTM PowerPack
Warning
Risk of injury The measuring points could be live.
–Use personal protective clothing and comply with the safety measures.
Condition
The KTM PowerPack has been removed.
–Prepare the special tool for measurement.
AVL DITEST HV Safety 2000 (70029068000)
–Start software HV Safety.
–Select "Insulation measurement".
310406-51
–Measure the voltage between the specified points.
High-voltage plug for KTM PowerPack FV pin 1–High-
voltage plug for KTM PowerPack FV pin 2
< 10 V
» If the specified value is not reached:
–Contact KTM customer service.
–Secure the KTM PowerPack in the transport and quar-
antine box, if necessary.
Transport system (70029020000)

INSULATION MEASUREMENT 5
15
310408-51
–Measure the resistance between the specified points.
High-voltage plug for KTM PowerPack FV pin 1–High-
voltage plug for KTM PowerPack FV pin gnd
Value as per HV Safety
» If the specified value is not reached:
–Contact KTM customer service.
–Secure the KTM PowerPack in the transport and quar-
antine box, if necessary.
Transport system (70029020000)
310407-51
–Measure the resistance between the specified points.
High-voltage plug for KTM PowerPack FV pin 2–High-
voltage plug for KTM PowerPack FV pin gnd
Value as per HV Safety
» If the specified value is not reached:
–Contact KTM customer service.
–Secure the KTM PowerPack in the transport and quar-
antine box, if necessary.
Transport system (70029020000)
5.2 Performing an insulation measurement on the discharge plug
Warning
Risk of injury The measuring points could be live.
–Use personal protective clothing and comply with the safety measures.
Condition
The KTM PowerPack has been removed.
–Prepare the special tool for measurement.
AVL DITEST HV Safety 2000 (70029068000)
–Start software HV Safety.
–Select "Insulation measurement".

5 INSULATION MEASUREMENT
16
310409-51
–Measure the voltage between the specified points.
Battery discharge plug FU pin 1–Battery discharge
plug FU pin 2
< 10 V
» If the specified value is not reached:
–Discharge intermediate circuit capacitors.
310410-51
–Measure the resistance between the specified points.
Battery discharge plug FU pin 1–Measuring point
Motor case
Value as per HV Safety
» If the specified value is not reached:
–Perform an insulation measurement on the motor elec-
tronics control unit. ( p. 17)

INSULATION MEASUREMENT 5
17
310411-51
–Measure the resistance between the specified points.
Battery discharge plug FU pin 2–Measuring point
Motor case
Value as per HV Safety
» If the specified value is not reached:
–Perform an insulation measurement on the motor elec-
tronics control unit. ( p. 17)
5.3 Performing an insulation measurement on the motor electronics control unit
Warning
Risk of injury The measuring points could be live.
–Use personal protective clothing and comply with the safety measures.
Condition
The KTM PowerPack and motor have been removed.
–Prepare the special tool for measurement.
AVL DITEST HV Safety 2000 (70029068000)
–Start software HV Safety.
–Select "Insulation measurement".

5 INSULATION MEASUREMENT
18
310412-51
–Measure the voltage between the specified points.
Measuring point HV+ –Measuring point HV−
< 10 V
» If the specified value is not reached:
–Discharge the intermediate circuit capacitors (motor
removed).
–Clean the sealing surface.
Info
Sealant on the contact surface between the motor
housing and the measurement tip can falsify
measurements.
310413-51
–Measure the resistance between the specified points.
Measuring point HV+ –Measuring point Motor case
Value as per HV Safety
» If the specified value is not reached:
–Perform an insulation measurement on the high-voltage
wiring harness. ( p. 19)
–Perform an insulation measurement on the stator.
( p. 20)
–Change the motor electronics control unit.
Last measure if none of the documented causes leads to
elimination of the fault
–Contact KTM customer service and send in the motor.