Summary of Contents for AVL DITEST HV SAFETY 2000
- Page 1 USER MANUAL AVL DITEST HV SAFETY 2000 ID no.: AT7718E Revision: Edition: 12 / 2018 Data subject to change without notice. All data valid at the time of going to print FUTURE SOLUTIONS FOR TODAY...
- Page 2 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...
- Page 3 AVL DiTEST HV Safety 2000 IMPORTANT SAFETY INSTRUCTIONS 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.
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Page 4: Warning And Safety Instructions
IMPORTANT SAFETY INSTRUCTIONS AVL DiTEST HV Safety 2000 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. -
Page 5: Summarised Safety Notes
AVL DiTEST HV Safety 2000 Summarised safety notes Summarised safety notes DANGER 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. - Page 6 Summarised safety notes AVL DiTEST HV Safety 2000 WARNING 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.
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Page 7: Safety Notes
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! - Page 8 AVL DiTEST HV Safety 2000 DANGER 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 Danger of death from electrical voltage in vehicles with high-voltage systems...
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Page 9: Table Of Contents
AVL DiTEST HV Safety 2000 Table of contents Table of contents IMPORTANT SAFETY INSTRUCTIONS ............I Warning and safety instructions ..............II Summarised safety notes ................III Safety notes ....................V General ..................... 1-1 General description ......................1-1 Safety instructions ......................1-2 Typographical conventions .................... - Page 10 Table of contents AVL DiTEST HV Safety 2000 4.3.6 Diode test ....................... 4-3 4.3.7 Equipotential bonding check ................4-3 4.3.8 Capacity measurment ..................4-3 Service screen ......................... 4-3 Maintenance and care ..............5-1 Visual check ........................5-1 Cleaning the product ......................5-1 Warranty...................
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Page 11: General
AVL DiTEST HV Safety 2000 General General 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) ... -
Page 12: Safety Instructions
General AVL DiTEST HV Safety 2000 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. -
Page 13: Operation Of Pc Programs
AVL DiTEST HV Safety 2000 General Standard text formats: bold Important text/text passages, parameter italic On screen dialogs and messages CAPITAL LETTERS Device designation and operating conditions MenuMenu item Selection of menu command through tapping on buttons List formats: Step-by-step instructions in a specified sequence ... -
Page 14: Design
General AVL DiTEST HV Safety 2000 Design 1.5.1 Overview The AVL DiTEST HV Safety 2000 comprises the following components AVL DiTEST HV Safety test module LEDs, blue and red/green Black protective cap to cover the black probe tip Black probe tip to connect to the black test adapter... -
Page 15: Top Side
Waiting for press of button to start self-test Red/green Firmware update with bootloader in progress Voltage > 10 V present at probe tips. Green (test voltage or high voltage generated by the AVL DiTEST HV Safety 2000) Blue Fig. 1-2 User manual... -
Page 16: Test Adapters
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. -
Page 17: Probe Tips
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 Danger of death from electrical voltage... - Page 18 General AVL DiTEST HV Safety 2000 User manual...
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Page 19: Commissioning
Please also refer to the AVL DSS user manual and the AVL DSS quick-reference guide. Hardware 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. -
Page 20: Data Entry And Settings
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 SettingsWorkshopPersons... -
Page 21: Performing A Measurement
Make sure that no other devices with an earth connection are connected to the test object at any time during a measurement. DANGER Danger of death from electrical voltage During measurements in high-voltage environment, the AVL DiTEST HV Safety 2000 may only be used, if the voltage source is non-grounded! User manual... -
Page 22: Results Protocols
Performing a measurement AVL DiTEST HV Safety 2000 Results protocols After each measurement a detailed results protocol can be generated. You can edit, print and save these protocols. By activating “Results – Automatic save” (see 2.2.1.1) a result protocol is generated and saved automatically after each measurement. -
Page 23: All-Pole Dc Voltage Measurement
You must read and observe these safety instructions. Click on Next. The AVL DiTEST HV Safety 2000 safety test is carried out: - Connect the probe tips briefly - Press and hold the test button on the red test adapter until the safety test has completed - The result of the safety test is displayed Place the probe tips on the test object. -
Page 24: Dc Voltage Measurement
You must read and observe these safety instructions. Click on Next. The AVL DiTEST HV Safety 2000 safety test is carried out: - Connect the probe tips briefly - Press and hold the test button on the red test adapter until the safety test has completed - The result of the safety test is displayed Place the probe tips on the test object. - Page 25 If no stable measured value is displayed: Start a new measurement Press and hold the test button on the red test adapter until a stable measured value is displayed If necessary, restart AVL DiTEST HV Safety 2000 or AVL DSS User manual...
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Page 26: Hv Insulation Measurement
You must read and observe these safety instructions. Click on Next. The AVL DiTEST HV Safety 2000 safety test is carried out: - Connect the probe tips briefly - Press and hold the test button on the red test adapter until the safety test has completed - The result of the safety test is displayed Select the HV measuring range. - Page 27 If no stable measured value is displayed: Start a new measurement Press and hold the test button on the red test adapter until a stable measured value is displayed If necessary, restart AVL DiTEST HV Safety 2000 or AVL DSS User manual...
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Page 28: Equipotential Bonding Check
- the specifications of the vehicle manufacturer - specifications according to ECE Regulation R 100 The AVL DiTEST HV Safety 2000 zero adjustment is carried out: - Place the tips of the probe at the 0-ohm zero point marker aid (blue cable clip) - Page 29 If no stable measured value is displayed: Start a new measurement Press and hold the test button on the red test adapter until a stable measured value is displayed If necessary, restart AVL DiTEST HV Safety 2000 or AVL DSS User manual...
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Page 30: Resistance Measurement
Click on Next. The AVL DiTEST HV Safety 2000 zero adjustment is carried out: - Place the tips of the probe at the 0-ohm zero point marker aid (blue cable clip) - Press and hold the test button on the red test adapter until the zero adjustment has... - Page 31 If no stable measured value is displayed: Start a new measurement Press and hold the test button on the red test adapter until a stable measured value is displayed If necessary, restart AVL DiTEST HV Safety 2000 or AVL DSS User manual 3-11...
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Page 32: Diode Test
You must read and observe these safety instructions. Click on Next. The AVL DiTEST HV Safety 2000 safety test is carried out: - Connect the probe tips briefly - Press and hold the test button on the red test adapter until the safety test has completed - The result of the safety test is displayed Place the probe tips on the test object. - Page 33 If no stable measured value is displayed: Start a new measurement Press and hold the test button on the red test adapter until a stable measured value is displayed If necessary, restart AVL DiTEST HV Safety 2000 or AVL DSS User manual 3-13...
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Page 34: Capacity Measurement
You must read and observe these safety instructions. Click on Next. The AVL DiTEST HV Safety 2000 safety test is carried out: - Connect the probe tips briefly - Press and hold the test button on the red test adapter until the safety test has completed - The result of the safety test is displayed Place the probe tips on the test object. - Page 35 If no stable measured value is displayed: Start a new measurement Press and hold the test button on the red test adapter until a stable measured value is displayed If necessary, restart AVL DiTEST HV Safety 2000 or AVL DSS User manual 3-15...
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Page 36: Insulation Monitor Check
You must read and observe these safety instructions. Click on Next. The AVL DiTEST HV Safety 2000 safety test is carried out: - Connect the probe tips briefly - Press and hold the test button on the red test adapter until the safety test has completed - The result of the safety test is displayed Attach the test leads to HV + and the chassis, as shown on the screen. - Page 37 If no stable measured value is displayed: Start a new measurement Press and hold the test button on the red test adapter until a stable measured value is displayed If necessary, restart AVL DiTEST HV Safety 2000 or AVL DSS User manual 3-17...
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Page 38: Sae J1766 Measurement
You must read and observe these safety instructions. Click on Next. The AVL DiTEST HV Safety 2000 safety test is carried out: - Connect the probe tips briefly - Press and hold the test button on the red test adapter until the safety test has completed... - Page 39 If no stable measured value is displayed: Start a new measurement Press and hold the test button on the red test adapter until a stable measured value is displayed If necessary, restart AVL DiTEST HV Safety 2000 or AVL DSS User manual 3-19...
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Page 40: Full Measurement
(see Fig. 3-1), a screen of safety instructions will appear. You must read and observe these safety instructions. The AVL DiTEST HV Safety 2000 safety test is carried out: - Connect the probe tips briefly - Press and hold the test button on the red test adapter until the safety test has completed - The result of the safety test is displayed Proceed as instructed on the screen. -
Page 41: Troubleshooting
Error messages The error messages that you may encounter are listed below together with possible solutions. Make sure that the AVL DiTEST HV Safety 2000 is correctly connected to the USB connection on the AVL MDS-PC. If necessary, disconnect the AVL DiTEST HV Safety 2000 from the USB connection on the AVL MDS-PC, wait a few seconds and then reconnect it. -
Page 42: Function Test
Please refer to section 3 “Performing a measurement”. 4.3.5 Resistance measurement A functional test of the resistance measurement of the AVL DiTEST HV Safety 2000 can be carried out as follows: Measure a known resistance. -
Page 43: Diode Test
AVL HV Safety Troubleshooting 4.3.6 Diode test A functional test of the diode measurement of AVL DiTEST HV Safety 2000 can be carried out as follows: Measure a known diode. Please refer to section 3 “Performing a measurement”. 4.3.7 Equipotential bonding check... - Page 44 Troubleshooting AVL DiTEST HV Safety 2000 User manual...
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Page 45: Maintenance And Care
DANGER Danger of death from electrical voltage If the AVL DiTEST HV Safety 2000, USB cable or test cables with probe tips are damaged, these must not be used until approval is given by a qualified expert. Cleaning the product... - Page 46 Maintenance and care AVL DiTEST HV Safety 2000 User manual...
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Page 47: Warranty
For the execution the date of the shipping note to the final customer does apply. Event of damage or loss In the event of damage or loss, please contact the respective AVL DiTEST office / the respective AVL DiTEST partner in your country. - Page 48 Warranty AVL DiTEST HV Safety 2000 User manual...
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Page 49: Technical Data
The AVL DiTEST HV Safety 2000 is only suitable for measurement of 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! - Page 50 1000 V and correspond to the norm EN 61010-31! DANGER 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! User manual...
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Page 51: Operating Data
AVL DiTEST HV Safety 2000 Technical data Operating data 95 x 220 x 45 mm Dimensions (w x l x h) Weight approx. 0.5 kg Ambient conditions Operation Ambient temperature 0 to +40 °C Relative humidity at max. +25 °C... -
Page 52: Metrology Specifications
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. DC voltage Range:... -
Page 53: High-Voltage Insulation Measurement
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. High-voltage insulation... -
Page 54: Resistance Measurement
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. Resistance measurement The measuring current depends on the measurement range and is 5mA maximum. -
Page 55: Capacity Measurement
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. Capacity measurement Range:... - Page 56 Technical data AVL DiTEST HV Safety 2000 User manual...
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Page 57: Index
AVL DiTEST HV Safety 2000 Index Index ll pole voltage measurement ....3-4 ew devices .......... 6-1 apacity measurement ....... 3-16 CAT overvoltage categories ....7-1 perating data ........7-3 Cleaning the product ....... 5-1 Operation of PC programs ....... 1-3 Commissioning ........ - Page 58 Index AVL DiTEST HV Safety 2000 User manual...