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Summary of Contents for STODIA HPS40-2
- Page 1 Operating manual High-voltage measurement adapter set HPS40-2 11.ST.2210.2440_BA_V02_EN...
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Page 2: Legal Notice
TRANSLATION OF THE ORIGINAL OPERATING MANUAL All rights reserved. All text, images and graphics are subject to copyright and other intellectual property laws. Copyright 2025 STODIA GmbH. Image sources Symbols for warnings, prohibitions, mandatory actions and standards are taken from publicly accessible sources, such as the Internet. -
Page 3: Table Of Contents
Product description ....................9 Scope of delivery ........................9 Design ............................10 3.2.1 High-voltage measurement adapter HPS40-2 (item no. 22102066) ........ 10 3.2.2 High-voltage bridging adapter HPS40-2 (item no. 22102436).......... 11 3.2.3 High-voltage adapter cable HPS40-2 (item no. 22102431) ..........11 Symbols and connections ...................... - Page 4 Contents 4.1.2 Testing that the circuit is de-energized ................20 4.1.3 Performing further measurements ..................20 4.1.4 Performing measurements using the high-voltage adapter cable ........20 Detaching the plug connections....................22 4.2.1 Detaching the plug connection of the high-voltage adapter cable ........22 Cleaning .............................
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Page 5: Introduction
With experience in both software and hardware development, STODIA GmbH is your dependable partner at every production stage, from prototyping to series production – MADE IN GERMANY. -
Page 6: Safety
This operating manual is only valid for the following product: Item number 22102440 Designation High-voltage measurement adapter set HPS40-2 Warning levels This chapter provides information about the warning levels used in this operating manual. DANGER Failure to observe the safety instructions WILL result in death or serious injury! -
Page 7: Important Safety Instructions
Safety Important safety instructions This chapter contains the safety instructions that must be observed when handling the product. DANGER Danger of fatal electric shock The electrical voltage in other systems is lethal and will cause death by electric shock. • Do not use the product for measurements on utility power circuits! •... -
Page 8: Intended Use
Contents Intended use Use the product only in accordance with this operating manual; otherwise the electrical hazard protection provided by the product can no longer be guaranteed. The product is a set of high-voltage measurement adapters for measuring high-voltage systems in electric vehicles at the on-board plug connection specified by the vehicle manufacturer. -
Page 9: Product Description
(1) Carrying case (2) USB stick with operating manual (3) High-voltage measurement adapter HPS40-2 (item no. 22102066) (4) High-voltage bridging adapter HPS40-2 (item no. 22102436) (5) High-voltage adapter cable HPS40-2 (item no. 22102431) -
Page 10: Design
Contents Design 3.2.1 High-voltage measurement adapter HPS40-2 (item no. 22102066) Product design: (1) EPIC socket for high-voltage adapter cable (2) Test sockets (see wiring diagram) (3) 20 A fuse – HV- (4) 20 A fuse – HV+ (5) “Hirschmann” plug (6) “Hirschmann”... -
Page 11: High-Voltage Bridging Adapter Hps40-2 (Item No. 22102436)
Product description 3.2.2 High-voltage bridging adapter HPS40-2 (item no. 22102436) Product design: (1) “Hirschmann” unit plug (2) 0.1 A fuse (3) Test socket (see wiring diagram) (4) “Hirschmann” plug 3.2.3 High-voltage adapter cable HPS40-2 (item no. 22102431) Product design: (1) Measurement adapter plug... -
Page 12: Warning Sign
Contents Position Description Carrying case nameplate Nameplate for measurement adapter cable Wiring diagram for high-voltage measurement adapter Nameplate for high-voltage measurement adapter Warning of electrical hazard Nameplate for bridging adapter Wiring diagram for high-voltage measurement adapter 3.3.1 Warning sign Figure Function The sticker warns of the electrical danger of the high-voltage measuring adapter. -
Page 13: Nameplates
Product description 3.3.2 Nameplates Figure Function The nameplates contain the following information: • Manufacturer information • Manufacturer part number • Product type • Serial number • User requirements You can use the serial number to track information relating to production. The following symbols are shown on the product stickers: Symbol Meaning... -
Page 14: Wiring Diagram
Contents Wiring diagram 3.4.1 High-voltage measurement adapter (CC item no. 22102066) 3.4.2 High-voltage bridging adapter (CC item no. 22102436) 11.ST.2210.2440_BA_V02_EN... -
Page 15: Technical Data
Product description Technical data 3.5.1 High-voltage measurement adapter Rated data Values Manufacturer number 22102066 Maximum rated voltage CAT I: DC 1000 V CAT II: DC 600 V CAT III: DC 300 V ≤ DC 60 V: 1000 mA Maximum rated current >... -
Page 16: High-Voltage Adapter Cable
Contents 3.5.3 High-voltage adapter cable Rated data Values Manufacturer number 22102431 Maximum rated voltage CAT I: DC 1000 V CAT II: DC 600 V CAT III: DC 300 V ≤ DC 60 V: 1000 mA Maximum rated current > DC 60 V: 2 mA Protection class II / double insulated Weight... -
Page 17: Operation
Operation Operation This chapter provides information about the following activities: • Startup • Detaching the plug connection • Cleaning • Storage and transportation • Disposal • Maintenance DANGER Danger of fatal electric shock The electrical voltage in high-voltage systems is lethal and will cause death by electric shock! Personal protection cannot be guaranteed if the high-voltage test adapter is faulty! •... -
Page 18: Startup
Contents Startup 4.1.1 Testing the high-voltage test adapter Before performing a certified test that the circuit is de-energized, you must always check that the high- voltage test adapter (item no. 22102066) is working correctly. To do so, conduct a continuity test using the high-voltage bridging adapter (item no. - Page 19 Operation Disconnect the high-voltage bridging adapter from the “Hirschmann” plug. Connect the high-voltage bridging adapter to the “Hirschmann” unit plug. Perform the continuity measurement on the laboratory safety sockets. ✓ If the continuity measurement is successful, you can use the high-voltage test adapter for the certified test that the circuit is de-energized.
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Page 20: Testing That The Circuit Is De-Energized
Contents 4.1.2 Testing that the circuit is de-energized You can determine that the circuit is de-energized on the laboratory safety sockets of the high-voltage test adapter. Requirement: • The high-voltage test adapter was tested successfully (see “Testing the high-voltage test adapter” chapter). - Page 21 Operation If you want to carry out measurements without the protection of safety resistors, you can use the supplied high-voltage adapter cable. Connect the plug to the EPIC socket on the high-voltage test adapter. Lock this connection by pushing the lever up. Connect the plug to the disconnected socket of the connection you want to test.
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Page 22: Detaching The Plug Connections
Contents Detaching the plug connections 4.2.1 Detaching the plug connection of the high-voltage adapter cable The plug connection has a manual locking mechanism. To release the plug connection: Move the lever downward. Pull the plug connection apart. ✓ The plug connection is now detached. Cleaning DANGER Danger of fatal electric shock... -
Page 23: Maintenance
Operation Maintenance Observe the safety instructions! National and local requirements for regular testing must be observed! Test the product for proper function at intervals of no more than 24 months. Contact the manufacturer to have a professional function test performed. 4.6.1 Replacing fuses DANGER... -
Page 24: Help
Help Warranty STODIA GmbH grants a warranty period of 24 months from the date of purchase. The warranty is valid for demonstrable defects in functional material and workmanship. Further information on the warranty conditions can be found in the terms and conditions on the manufacturer’s website. - Page 26 STODIA GmbH Battery & Diagnostics Technology Im Freitagsmoor 45 38518 Gifhorn, Germany Tel.: +49 (0) 53 71 / 945 93 96 – 0 info@stodia.de www.stodia.de Translation of the original operating manual. Subject to technical changes.
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