TKR Group 83 30 2 449 661 User manual

HV Adapter Set
Owner’s Manual
83 30 2 449 661
Translation of the original owner’s manual

2
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Europe
World-wide
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C Patent no. XXX
This owner‘s manual is protected by copyright. Any use outside the boundaries of copyright law without the consent of the manufacturer is not permitted
and is punishable by law. This also applies to the extraction of individual illustrations and the use of texts in excerpt form.

3
Safety
1.1 Information regarding this manual 4
1.2 Explanation of symbols 4
1.3 Labelling 5
1.4 Scope of supply 6
1.5 Safety instructions 7
Technical data
2.1 Technical data 8
2.2 Device components 9
2.3 Operating conditions 9
Application
3.1 Operating principles 10
3.2 Basic principles for handling the HV Adapter Set 10
3.3 Testing before use 11
3.4 Use 12
3.5 Checking to make sure there is no live voltage with
two-pole voltage tester 13
3.6 Checking to make sure there is no live voltage with
multimeter 14
3.7 Sources of faults 15
Maintenance
4.1 Troubleshooting 16
4.2 Maintenance 16
4.3 Spare parts 16
Service
5.1 Disposal 16
5.2 Liability 17
5.3 Warranty 18
5.4 EU Declaration of Conformity 19
1.
2.
3.
4.
5.

4
1.1 Information regarding this manual
Follow owner’s manual!
Observe the general
information!
Warning!
General source of danger
High voltage!
Danger to life
Warning!
Hot surface
1.2 Explanation of symbols
In this owner’s manual, some sections use internationally known warning symbols, warning notes and general
instruction symbols.
The individual symbols are explained below. Follow all the instructions and safety rules.
Please note the...
Arrow to clarify
compression
For more information,
see section…
Arrow showing direction
cTUVus Certification
CE symbol
State-of-the-art
The High Voltage Adapter Set (HV Adapter Set) is state of the
art. To ensure that the device operates safely, it must be oper-
ated in a proper and safe manner.
Technical modifications
In the interests of quality assurance, we reserve the unre-
stricted right to carry out technical modifications as a result
of further technological developments and product improve-
ments without prior notification.
Reading the owner’s manual
Before using the HV Adapter Set, read the owner‘s manual
carefully. These instructions must always be available on site
where the product is in use. In addition to the instruction
manual and the binding provisions of the accident preven-
tion regulations applicable at the place of use, the general
(accepted) rules for safety compliance and professional work-
ing must be observed.
Handling
All handling necessary to ensure correct operation is de-
scribed in the owner‘s manual. No methods of working oth-
er than those approved by the manufacturer may be used.
Faults
If problems arise, the operator may only eliminate those
problems through their own actions where the correspond-
ing rectification measure is described.
TÜVRheinland
CUS

5
A
L
B
M
B
D
O
C
N
G
R
E
P
F
Q
KJIH
S
1.3.1
1.3.3
1.3.2
1.3.4
1.3 Labelling
1.3.1 HV Adapter labelling, top
A Three stickers (Warning!, High voltage!,
Follow owner‘s manual!)
B Designation of measurement points
C Warranty seal
D Seal with reference to trained personnel
1.3.3 Adapter end labelling, top
L Contact pins
M Thermal sticker
N Locking clamp
O Sticker referring to hot surface
1.3.2 HV Adapter labelling, bottom
E Manufacturer’s label
F Item number
G Connection diagram
H Company address
I Voltage, protection class and serial number
J TÜV symbol
K CE symbol
1.3.4 Adapter end labelling, bottom
P Connection diagram
Q TÜV symbol
R CE symbol
S Data on max. current

6
1.4.1
A
B
C
GFED
HA Owner‘s manual
B HV Adapter
C 2 x Reducer 2 /4mm
D Adapter cable pin
housing, Kostal
E Adapter cable socket
housing, Kostal
F Adapter cable pin
housing, Hirschmann
G Adapter cable socket
housing, Hirschmann
H Case
1.4 Scope of supply

7
1.5 Safety instructions
If any abnormality is discovered, the HV Adapter Set must not be used.
Please contact Service ( 5.3).
In principle, the HV Adapter Set is approved
solely for the purpose for which the manufac-
turer has designed it.
Only genuine accessories may be used. Do
not use anything other than the genuine
tools or genuine accessories or there will be
a high risk to safety.
Ensure that only trained and instructed per-
sonnel use the device!
Use of the device by personnel who have not
been trained and not instructed is prohibited.
Ensure that the owner's manual is made avail-
able to operating personnel. Before operat-
ing this device for the first time, each opera-
tor must read this owner's manual carefully.
This manual must always be available on site
where the product is used. The owner's man-
ual must be followed along with the binding
provisions of the accident prevention regula-
tions which apply at the place of use and the
general and accepted regulations for safe
and professional work.
The HV Adapter Set must be visually inspect-
ed every time before it is used.
The HV adapter set must be checked for oper-
ation every time before it is used.
Before using the HV Adapter Set, check
whether the relevant thermal sticker on the
adapter ends is in order.
3.3.5
Never throw the HV Adapter Set or allow it
to fall.
Never use the HV Adapter Set for purposes
for which it was not designed.
The HV Adapter Set must only be used in am-
bient temperatures of at least 5 °C / 41 °F to a
maximum of 45°C /113 °F .
The HV Adapter Set must never be used in
potentially explosive areas.
Before using, always check all the compo-
nents for damage.
If any defect or abnormality is found on the
HV Adapter Set, it must not be used. Contact
your service partner!

8
120.7
180
76.3
HV–
SCR
HV+
HV–
SCR
HV+
HV–
SCR
HV+
HV+
SCR
HV–
Art. Nr. 77-001070
HV–
SCR
HV+
47 kΩ
47 kΩ
77-001104
47 kΩ
47 kΩ
HV–
SCR
HV+
77-001105
Adapter end Adapter end
2 .1.1
2.1.2
HV Adapter
2.1 Technical data
Model number 83 30 2 449 661
Weight 0.5 kg
Dimensions (W x H x D) 180 x 76.3 x 120.7 mm
Ambient temperature (storage) -40°C to +60°C / -40°F to +140°F
Ambient temperature (operation) +5°C to +45 °C / +41°F to +113°F
Ambient humidity to 95% (non-condensing)
Umax 1000V DC
Protection IP20, CAT I
Impedance 47 kΩ HV +, 47kΩ HV-
Adapter cable length 700 mm
Connection diagram

9
2.2.1.
2.2 Device components
6 7 8
1
9
2.2.1 HV Adapter Set
HV Adapter
Annular contact sockets, 4 mm
Labelling of annular contact sockets
Plug connector HV Adapter (socket)
Adapter end (pin housing)
1
2
3
4
5
2.3 Operating conditions
Voltage supply
No additional voltage supply is needed.
Climate conditions
Storage temperature: -40°C to +60°C / -40°F to +140°F
Operating temperature: +5°C to +45°C / +41°F to +113°F
Environmental humidity: up to 95% (not dew-forming)
Protection: IP20, CAT I, Degree of contamination 2
Climate class: 3K3
Electromagnetic compatibility (EMC)
According to GS 95002/GS 95024-2 (IEC61000)
• Interference immunity to voltage peaks on data lines
• Interference immunity to voltage peaks on signal and data lines
• Measurement of cable-conducted interference of electric motors, Suppression Class 5
• Measurement of cable-conducted electronic component interference
• Immunity to irradiation, 50 V/m from 0-220 MHz for all components
• Irradiation test with GSM (D-Netz) and DCS1800 (E-Netz) portable telephone appliances
2
Adapter cable pin housing, Kostal
Adapter cable socket housing, Kostal
Adapter cable pin housing, Hirschmann
Adapter cable socket housing, Hirschmann
3
3
4
4
5 5 5 5
6
7
8
9

10
3.1 Operating principles
The HV Adapter is used in workshops to make sure there is no live voltage or insulation defects on HV motor vehi-
cle on-board electrical systems. Different types of plug connectors are therefore included in the scope of supply for
connection to the different HV components.
A trained user can use suitable testing and measurement instruments to check the voltage or use guided trouble-
shooting to find faults on the HV system.
As a rule, never work on live parts of the electrical system or equipment. Before starting work, live parts must there-
fore be de-energised and this state checked and guaranteed for the duration of the work.
The testing and measurement instruments used must be approved and must be suitable for the voltage
being measured (label on the instrument at least CAT I and the max. operating voltage present, e.g.
CAT I 1000V).
3.2 Basic principles for handling the HV Adapter Set
Risk of injury
Please make sure that you and your staff han-
dle the HV Adapter Set correctly.
It is expressly forbidden to misuse the HV
Adapter Set or to use it for any other purpose.
The HV Adapter Set must only be used for the
purpose for which it was designed.
Warranty
The manufacturer accepts no liability for dam-
age or injury caused by improper repair or use of
third-party replacement parts.
No warranty will be provided for damage caused
to the device due to the HV Adapter Set being
used incorrectly.
Environment
Make sure that the HV Adapter Set is set up in
a work area which is free from sources of heat
(max. 45°C / 113 °F), corrosive liquids, greases
and oils.
Leave to acclimatise before starting. Avoid
condensation formation.
Declaration of Conformity
The HV Adapter Set has been manufactured and
tested in accordance with the European directive.
The Declaration of Conformity is included with
this instruction manual.
5.4

11
3.3 Testing before use
Check the HV Adapter Set for any damage
every time before using it.
Always carry out a visual inspection of the
spring contacts before use.
A self-test must always be carried out on the
tool to make sure that it is in perfect working
order before using it.
Check the measurement instrument for dam-
age and check operation before carrying out
any measurement.
During the self-test, all the plugs and sockets must be con-
nected to each other and the adapter ends plugged into the
HV Adapter and locked.
3.3.1 First press the knob (1), then open the cover (2).
3.3.2 Plug in plug (3), then press lock (4) in the direction
of the arrow.
3.3.3 Test set-up for self-test.
3.3.4 Test set-up for resistance tests.
Now carry out the following resistance tests with a suitable
measurement instrument and compare the results with the
table below:
If the measurement values shown above do
not appear during the self-test, the HV adapt-
er set must not be used!
HV– to HV– Resistance 94kΩ, Tolerance 1%
HV+ to HV+ Resistance 94kΩ, Tolerance 1%
SCR to SCR Resistance 0 Ω
HV+ to HV– Resistance > 10 MΩ
HV– to HV+ Resistance > 10 MΩ
HV+ to SCR Resistance > 10 MΩ
HV– to SCR Resistance > 10 MΩ
3.3.3
3.3.4
3.3.1 3.3.2
1
2
3
4

12
3.4.1
3.4.1 - 3.4.4 Connecting HV components
Connect each adapter cable needed to the HV Adapter
and secure it with the clamp.
Now connect the corresponding pin / socket housing of
the adapter cable to the HV components.
3.4.2
Connection to
HV components
with pin or socket
contact
Connection to
HV components
with pin or socket
contact
3.4.3 3.4.4
3.3 Testing before use
3.4 Use
°
0
8
F
1
8
C
2
°
3.3.5
°
0
8
F
1
8
C
2
°
7
3
3.3.5 Thermal sticker
Before using the HV Adapter Set, check
whether the relevant thermal sticker on the
adapter ends is in order (white dot in the cen-
tre).
If the dot in the centre of the thermal sticker
has gone black, the temperature has exceeded
82°C /180°F and the adapter must not be used!
When connecting two HV components, never
connect the HV+ and HV- connections to the
opposing HV+ and HV- connections.
If there is bridging or short circuiting, the
adapter cables must be changed immediately.

13
3.5.1 3.5.2 3.5.3
3.5 Checking to make sure there is no
live voltage with two-pole voltage tester
The supplied reducers are used depending on the
diameter of the test connections (2mm/4mm) of
the testing / measurement instrument used and
are plugged into the corresponding measure-
ment sockets.
Never use two-pole voltage testers with 2mm
test connections without the reducers.
The voltage tester used must be approved
and must be suitable for the voltage being
tested.
Suitable testing / measurement instruments
must be used to make sure there is no live
voltage when testing with the HV Adapter
Set!
(Label on the testing / measurement instru-
ment at least CAT I and the max. operating
voltage present, e.g. CAT I 400 V)
Check the testing / measurement instrument
for damage and check operation before car-
rying out any measurement.
Check the testing / measurement instrument with a known
voltage source to make sure it is operating properly.
3.5.2 – 3.5.3 Testing:
• Voltage tester across HV+ and HV-
• Voltage tester across HV+ and SCR
• Voltage tester across HV- and SCR
The voltage tester may only display voltages below 60 V dur-
ing the tests. If there are deviations, the procedure must be
repeated with a multimeter.
During the testing procedures, make sure that
you only select the measurement sockets on
the side of the adapter end plugged in!
The connections with the same designation
are not connected to one another!
If the voltage is higher than 60 V DC, the
entire HV system must be regarded as
DANGEROUSLY ACTIVE.
You must not continue working on live HV
components!
Note that the deviation is greater when
using testing / measurement instruments
with a lower internal resistance.
A voltage tester usually has an internal resistance of 200kΩ.
When the voltage which appears is 60 V, the
actual voltage is approx. 88V
3.7
3.6
Internal resistance Deviation
5MΩ approx. 2%
1MΩ approx. 9%
200kΩ approx. 32%
3.5.1

14
3.6 Checking to make sure there is no
live voltage with multimeter
The testing / measurement instruments used
must be approved and must be suitable for
the voltage being tested.
The test leads used must be touch protected
and approved and must be suitable for the
voltage being tested.
Suitable testing / measurement instruments
must be used to make sure there is no live
voltage when testing with the HV Adapter
Set!
(Label on the testing / measurement instru-
ment at least CAT I and the max. operating
voltage present, e.g. CAT I 1000 V)
Check the testing / measurement instrument
for damage and check operation before car-
rying out any testing procedures.
Set the testing / measurement instrument to a suitable DC
voltage measurement range. Switch off the automatic meas-
urement range switching.
Check the testing / measurement instrument with a known
voltage source to make sure it is operating properly.
3.6.1 – 3.6.2 Testing
To test potentials against the screen (SCR), first use suitable
test leads to connect the COM port of the testing / measure-
ment instrument to the SCR (screen) connection of the HV
Adapter Set.
Connect the (V) connection of the testing / measurement
instrument to the HV+ or HV- connection being measured.
The resulting voltage can now be read on the meter.
To test voltages across HV+ and HV-, connect the COM port
of the testing / measurement instrument to the HV- connec-
tion of the HV Adapter Set and the (V) connection of the test-
ing / measurement instrument to the HV+ connection of the
HV Adapter Set.
The voltage of each testing procedure must be zero.
The testing / measurement instrument must
be set to DC voltage and the automatic
measurement range change-over must be
switched off.
During the testing procedures, make sure that
you only select the measurement sockets on
the side of the adapter end plugged in!
Connections with the same designation are
not connected to one another!
If the voltage is higher than 60 V DC, the
entire HV system must be regarded as
DANGEROUSLY ACTIVE.
Be aware of possible errors in the voltage
check due to the voltage drop across the
internal resistance.
You must not continue to work on live HV
components!
3.6.23.6.1
3.7

15
3.7.23.7.1
7
3
3.7.3
3.7 Sources of faults
Testing results / testing errors
The HV Adapter Set contains two 47,000 ohm resistors in
each adapter connection plug in the HV+ line and the HV-
line.
These resistors cause a voltage drop during the voltage test-
ing which depends on the internal resistance of the testing /
measurement instrument used. This voltage drop causes the
reading on the testing / measurement instrument to be low-
er than the actual voltage.
On a standard testing / measurement instrument with an
internal resistance of 10MΩ (10,000,000 ohms), the voltage
drop in the HV adapter is approx. 1% of the actual voltage.
In this case, the measured voltage is 1% less than the actually
available voltage.
Internal resistance Deviation
5MΩ approx. 2%
1MΩ approx. 9%
200kΩ approx. 32%
Note that the deviation is greater when us-
ing testing / measurement instruments with
a lower internal resistance.
In the event of misuse, the resistors integrat-
ed in the adapter ends heat up!
3.3.5
Example:
If the internal resistance of the testing / measurement instru-
ment is 200kΩ and the measured voltage is 60V, the actual
voltage across the HV accumulator is approximately 88V.
3.7.1 – 3.7.3 Defective contact protection
If, when using the Kostal socket housing adapter cable, the
contact protection device on the connector strip of the HV
storage unit cannot be pulled back into its initial position, the
adapter cable must no longer by used. Check whether the
connector strip on the HV storage unit or the adapter cable is
defective and replace the adapter cable as necessary.
2.2.1 7Adapter cable socket housing, Kostal

16
4.2 Maintenance
4.3 Spare Parts
Cleaning
Apart from occasional cleaning with a dry, lint-free cloth, the
HV Adapter Set is maintenance-free.
4.1 Troubleshooting
5.1 Disposal
Devices and machinery and components of devices and machinery must be disposed of in accordance
with the laws, regulations and other stipulations of the country in which they are located.
We recommend that disposal be undertaken by licensed professional operators.
The modules and units have been developed to be environmentally compatible and suitable for recycling.
According to the EU Directive 2000/53/EC, these parts must be taken to authorised collection points.
The manufacturer does not promise to take back modules and units of electrical equipment or electrical equip-
ment in its entirety or batteries free of charge.
Malfunction Problem Remedy Chapter
The measurement values specified are
not measured during the self-test.
There is a fault in the adapter cable
(e.g. due to incorrect use). Change adapter cables. 3.3
The colour of the thermal sticker has
changed from white to black in the
center.
The integrated resistors have heated
up due to incorrect use. Change adapter cables. 3.4
Service
Do not carry out any service activities on this device.
TKR item number Designation pc.
BGR-BMW-10000066 HV Adapter 1
BGR-BMW-10000067 Adapter cable pin housing, Kostal 1
BGR-BMW-10000068 Adapter cable socket housing, Kostal 1
BGR-BMW-10000069 Adapter cable pin housing, Hirschmann 1
BGR-BMW-10000070 Adapter cable socket housing, Hirschmann 1
99-000439 Adapter XA 2/4 2
DOK-BMW-00000008 Owner's Manual 1
WZK-BMW-00000004 HV Adapter Set V 1.0 case 1
Other languages, accessories and spare parts:
www.tkr-service.com

17
5.2 Liability
Neither this restriction of liability nor any other parts of this guide are intended to exclude the liability of the TKR
Group in respect of death of or injury to a person in the event of negligence or deliberate intent, where any such
exclusion is legally inadmissible.
However, taking the above clause duly into account, in each legally admissible case the maximum possible sum
which may be claimed from TKR is restricted to USD 50. This applies irrespective of the legal basis for the claim. The
existence of more than one basis for the claim or claims does not increase this amount.
Irrespective of this, however, TKR does not otherwise bear liability - on whatever legal grounds - for:
• loss of income or profit,
• loss of reputation, commercial expectations or company goodwill,
• loss of or damage to operating equipment, operating installations or other
resources used in connection with the HV Adapter Set,
• any indirect damages or knock-on damages caused due to deliberate intent,
negligence or unsatisfactory fulfilment of contract, to the extent legally
admissible.
Apart from the expressly assured properties, TKR provides no assurance on any further properties of any kind,
neither directly nor indirectly, nor tacitly.

18
A warranty period of 24 months is guaranteed for merchants for HV Adapter Sets from TKR Spezialwerkzeuge
GmbH in the event of defects which can be traced back to material or manufacturing faults. Otherwise, the stat-
utory conditions governing warranty periods and our General Terms and Conditions of Sale and Supply apply.
High voltage components are not included.
The warranty period begins on the date of delivery, as specified on the invoice or delivery note. The warranty is
valid for the user/customer provided that the HV Adapter Set is obtained from an authorised sales outlet and is
used as described in the instructions and for the purposes for which it was designed.
The warranty is voided if the HV Adapter Set is used for purposes other than those for which it was designed.
The warranty is also voided if the HV Adapter Set is not used as described in the owner‘s manual.
In the event of defect or fault, TKR Spezialwerkzeuge GmbH shall only repair or replace faulty parts at its own
discretion.
Service address
TKR Spezialwerkzeuge GmbH
Service
Am Waldesrand 9-11
D-58285 Gevelsberg (Germany)
5.3 Warranty
Phone [phone]
Fax [phone]
E-Mail [e-mail]

EU Declaration of Conformity
For the purposes of the low voltage directive
2014/35/EU
Manufacturer: TKR Spezialwerkzeuge GmbH
Am Waldesrand 9–11
58285 Gevelsberg, Germany
Person authorised to compile
the technical documentation: Thorsten Weyland
Type of tool: HV Adapter Set
Type designation: 83 30 2 449 661
Developed and constructed in accordance with
the standards and guidelines listed by
TKR Spezialwerkzeuge GmbH
Am Waldesrand 9–11
58285 Gevelsberg (Germany)
Harmonised standards used: EN 61010-1 : 2010
Serial number range: 00001–10000
Low voltage directive: 2014/35/EU
As manufacturer, we declare: Theproductsmarkedaccordinglyfulllthe
requirements of the directive and standards listed.
Gevelsberg, 20.01.2017 Thorsten Weyland
Technical Manager

DOK-BMW-00000009, Vers. 18.02
Am Waldesrand 9–11
D-58285 Gevelsberg (Germany)
Phone [phone]
Fax [phone]
E-Mail [e-mail]
Web www.tkrgroup.com
Other languages, accessories and spare parts:
www.tkr-service.com