AVL DITEST DCIR-PROBE, User Manual

Page 1: ...P 120 DCIR PROBE INTERNAL RESISTANCE PROBE DIRECT CURRENT INTERNAL RESISTANCE PROBE ID number AT7949EN Revision 02 Version 05 22 Data subject to change All data valid at the time of printing PASSION INNOVATES FUTURE ...

Page 2: ...ts reserved The contents of this publication in 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 or for any damage that may arise as a result ...

Page 3: ...al Resistance with One Module 24 6 3 2 Module Internal Resistance with Three Module 29 6 4 Measuring Contact Resistance 34 6 4 1 Contact Resistance with One Module 36 6 4 2 Contact Resistance with Three Modules 40 6 5 Measuring Contact Resistance 44 6 5 1 Contact Resistance with One Module 46 6 5 2 Contact Resistance with Three Modules 50 6 6 Displaying Device Data 54 7 Troubleshooting 56 7 1 Intr...

Page 4: ...IRP 120 11 Index 62 ...

Page 5: ...f a battery module and the resistance between modules busbar of an electric vehicle traction battery Any use beyond its intended use as well as non compliance with the mandatory requirements and safety measures will void the warranty and any associated liability 1 2 Target Group The IRP 120 is intended for testing organizations vehicle repair service shops or similar establishments It is intended ...

Page 6: ...y symbols are used in this documentation DANGER DANGER indicates a dangerous situation which if not avoided leads to death or serious injury WARNING WARNING indicates a dangerous situation which if not avoided can lead to death or serious injury CAUTION CAUTION indicates a dangerous situation which if not avoided can lead to slight or moderate injury Additional safety symbols Failure to comply wit...

Page 7: ...perating errors that can lead to damage to property or data loss Information This text refers to important information or instructions Not following these instructions will significantly prevent or hinder the successful execution of the actions described in this documentation ...

Page 8: ... pull on the cable when unplugging it from the electrical outlet Grab and pull on the plug to unplug it 5 Let the device cool down completely before putting it away Place the hoses loosely around the device for storage 6 To reduce the risk of fire do not operate the device near open containers with flammable liquids gasoline 7 Ensure adequate ventilation when working on combustion engines 8 Keep h...

Page 9: ...icles particularly disassembly work Risk of death from electric voltage on vehicles equipped with high voltage systems For live line work specific safety and vocational training conditions apply Make sure to comply with these conditions in all situations Risk of death from electric voltage on vehicles equipped with high voltage systems Make sure that all necessary safety precautions have been take...

Page 10: ...be performed by specialists who are trained in this area and who are aware of the associated dangers v WARNING Risk of death due to electric voltage The product may only be repaired by the supplier plant or by trained specialists Note The device may only be operated with accessories and consumables supplied by AVL DiTEST or approved by AVL DiTEST ...

Page 11: ...mp cable red BV8320 Current clamp cable black BV8321 Test probe cables BV8319 Test probe red EU8005 Test probe black EU8006 User Manual AT7949D Spare parts Part ID number Current clamp cable red BV8320 Current clamp cable black BV8321 Test probe cables BV8319 Test probe red EU8005 Test probe black EU8006 Rubber base MR7459 ...

Page 12: ...llustration shows the configuration of the IRP 120 Fig 1 1 IRP 120 measuring module 2 Air vents 3 LEDs 4 USB cable connection to PC 5 Air vents 6 Red connection positive current clamp 7 Blue connection test probes 8 Black connection negative current clamp v 5 1 2 3 8 4 6 7 ...

Page 13: ... IRP 120 is ready for operation Blue flashing IRP 120 is starting Bootload procedure Status LED LED Status Sensor No light No power supplied to IRP 120 No connection to tester Green continuously lit IRP 120 is ready for operation Green flashing quickly Measurement is running Red flashing quickly Error e g the checksum of the installed firmware is wrong ...

Page 14: ...lies with the surge voltage values of the surge voltage category CAT II 600 V CAT III 300 V Do not conduct measurements on circuits connected directly to the mains Use the IRP 120 only for measurements at the battery The 1 8 m measuring cables are connected to the IRP 120 Fig 2 Cables DANGER Kelvin clamps Plugs ...

Page 15: ...age values of the surge voltage category CAT II 600 V CAT III 300 V Do not conduct measurements on circuits connected directly to the mains Use the IRP 120 only for measurements at the battery The 1 8 m measuring cables are connected to the IRP 120 Fig 3 DANGER Black measuring probe negative Button Red measuring probe positive Plugs ...

Page 16: ...its connected directly to the mains Use the IRP 120 only for measurements at the battery Risk of death due to electric voltage Only use measuring equipment provided by AVL DiTEST If using general measuring adapters test probes measuring clamps etc make sure that they are suitable and approved for measuring and test voltages up to 1000 V and meet the EN 61010 31 standard Fig 4 DANGER DANGER Protect...

Page 17: ...der to use the IRP application If AVL DiTEST DSS Manager is already installed the IRP application can also be installed If AVL DiTEST DSS Manager is not yet installed it can be installed together with the IRP application in a single package The installer is available at the link shown below 1 Navigate to https ext avlditest com customer SitePages SoftwareDownload aspx 2 Log in 3 Click on DOWNLOAD ...

Page 18: ...l Install IRPApplication x x x x exe If AVL DITEST DSS Manager is not installed install Install DSSManager IRPApplication x x x x exe 5 2 2 Software Update Updating the operating software used in the device takes place automatically via the PC Make sure that the latest version of the operating software is installed on the PC ...

Page 19: ...IRP 120 Working with the IRP 120 User Manual 17 6 Working with the IRP 120 6 1 Starting the IRP 120 Start the software by clicking Start Programs DiTEST DSS Click Diagnostics IRP Fig 7 ...

Page 20: ...Working with the IRP 120 IRP 120 18 User Manual A start screen appears Fig 8 ...

Page 21: ...20 User Manual 19 6 2 Self Test If an error occurs carry out a self test first To conduct a self test proceed as follows 1 Start the software by clicking Start Programs DiTEST DSS 2 Click Diagnostics IRP Fig 9 A start screen appears ...

Page 22: ...120 20 User Manual 3 Click Selftest Fig 10 4 Pay attention to the instructions on the screen and disconnect the cables shown Fig 11 5 The self test is performed and the result is displayed Use F8 Next to return to the start screen ...

Page 23: ...IRP 120 Working with the IRP 120 User Manual 21 Fig 12 ...

Page 24: ...nual 6 3 Module Internal Resistance Measurement To measure the internal resistance in a module proceed as follows 1 On the start screen click Module internal resistance Fig 13 2 Enter the name of the test engineer and set a password 3 Click Next ...

Page 25: ...23 Fig 14 4 Choose whether you are taking the measurement in one or three modules and click Next Fig 15 A screen opens where you can enter the test parameters The following two chapters describe how to take a measurement using one or three modules ...

Page 26: ...nal resistance using one module 1 As described in Module Internal Resistance Measurement navigate to the parameter entry screen 2 Enter the module information Information Values outside the limits cannot be entered Values above the limits cannot be entered If an entered value is too low it will be displayed in red Fig 16 Enter Parameters screen ...

Page 27: ...s that are too low are red Information Clicking Help makes it possible to display the automatically calculated parameter limits Information The entered parameter limits can be saved by clicking Save and can then be retrieved from the drop down menu 3 Click Next ...

Page 28: ...RP 120 26 User Manual 4 Connect the positive red and negative black clamps as shown in the software Information Clicking Placement opens a view of the exact placement of the individual components Fig 18 Probe connection overview ...

Page 29: ...f the clamp and measuring probes 5 Press and hold the button on the red test probe to start the measurement 6 Connect the positive red and negative black test probe The measurement starts After the measurement is taken a tone is heard and another area can be measured ...

Page 30: ...To stop measuring let go of the test button 8 Click Report to view the test report If multiple measurements were taken the test report is expanded to include each additional measurement Click Edit to add comments 9 Click Save to save the record Fig 20 ...

Page 31: ...odules proceed as described below 1 As described in Module Internal Resistance Measurement navigate to the parameter entry screen 2 Enter the module information Information Values outside the limits cannot be entered Values above the limits cannot be entered If an entered value is too low it will be displayed in red Fig 21 Enter Parameters screen ...

Page 32: ...s that are too low are red Information Clicking Help makes it possible to display the automatically calculated parameter limits Information The entered parameter limits can be saved by clicking Save and can then be retrieved from the drop down menu 3 Click Next ...

Page 33: ...RP 120 User Manual 31 4 Connect the positive red and negative black clamps as shown in the software Information Clicking Placement opens a view of the exact placement of the individual components Fig 23 Probe connection overview ...

Page 34: ...f the clamp and measuring probes 5 Press and hold the button on the red test probe to start the measurement 6 Connect the positive red and negative black test probe The measurement starts After the measurement is taken a tone is heard and another area can be measured ...

Page 35: ...of the test button Fig 25 Placement of the clamp and measuring probes 8 Click Report to view the test report If multiple measurements were taken the test report is expanded to include each additional measurement Click Edit to add comments 9 Click Save to save the record Fig 26 ...

Page 36: ... 120 34 User Manual 6 4 Measuring Contact Resistance Measure the contact resistance in a module as follows 1 On the start screen click Contact Resistance Fig 27 2 Enter the name of the test engineer and set a password 3 Click Next ...

Page 37: ...IRP 120 Working with the IRP 120 User Manual 35 Fig 28 4 Choose whether you are taking the measurement in one or three modules and click Next Fig 29 ...

Page 38: ...a module as follows 1 As described in Measuring Contact Resistance navigate to the parameter entry screen 2 Enter the module information Information Values outside the limits cannot be entered Values above the limits cannot be entered If an entered value is too low it will be displayed in red Fig 30 Enter Parameters screen ...

Page 39: ...Clicking Help makes it possible to display the automatically calculated parameter limits Information The entered parameter limits can be saved by clicking Save and can then be retrieved from the drop down menu 3 Click Next 4 Connect the positive red and negative black clamps as shown in the software ...

Page 40: ...iew of the exact placement of the individual components Fig 33 5 Press and hold the button on the red test probe to start the measurement 6 Connect the positive red and negative black test probe The measurement starts After the measurement is taken a tone is heard and another area can be measured ...

Page 41: ...P 120 User Manual 39 7 Click Report to view the test report If multiple measurements were taken the test report is expanded to include each additional measurement Click Edit to add comments 8 Click Save to save the record Fig 34 ...

Page 42: ...hree modules as follows 1 As described in Measuring Contact Resistance navigate to the parameter entry screen 2 Enter the module information Information Values outside the limits cannot be entered Values above the limits cannot be entered If an entered value is too low it will be displayed in red Fig 35 Enter Parameters screen ...

Page 43: ...IRP 120 Working with the IRP 120 User Manual 41 Fig 36 Values that are too low are red ...

Page 44: ... parameter limits Information The entered parameter limits can be saved by clicking Save and can then be retrieved from the drop down menu 3 Click Next 4 Connect the positive red and negative black clamps as shown in the software Fig 37 Information Clicking Placement opens a view of the exact placement of the individual components ...

Page 45: ...tive red and negative black test probe The measurement starts After the measurement is taken a tone is heard and another area can be measured 7 Click Report to view the test report If multiple measurements were taken the test report is expanded to include each additional measurement Click Edit to add comments 8 Click Save to save the record Fig 39 ...

Page 46: ... 120 44 User Manual 6 5 Measuring Contact Resistance Measure the contact resistance in a module as follows 1 On the start screen click Contact Resistance Fig 40 2 Enter the name of the test engineer and set a password 3 Click Next ...

Page 47: ...IRP 120 Working with the IRP 120 User Manual 45 Fig 41 4 Choose whether you are taking the measurement in one or three modules and click Next Fig 42 ...

Page 48: ...a module as follows 1 As described in Measuring Contact Resistance navigate to the parameter entry screen 2 Enter the module information Information Values outside the limits cannot be entered Values above the limits cannot be entered If an entered value is too low it will be displayed in red Fig 43 Enter Parameters screen ...

Page 49: ...Clicking Help makes it possible to display the automatically calculated parameter limits Information The entered parameter limits can be saved by clicking Save and can then be retrieved from the drop down menu 3 Click Next 4 Connect the positive red and negative black clamps as shown in the software ...

Page 50: ...iew of the exact placement of the individual components Fig 46 5 Press and hold the button on the red test probe to start the measurement 6 Connect the positive red and negative black test probe The measurement starts After the measurement is taken a tone is heard and another area can be measured ...

Page 51: ...P 120 User Manual 49 7 Click Report to view the test report If multiple measurements were taken the test report is expanded to include each additional measurement Click Edit to add comments 8 Click Save to save the record Fig 47 ...

Page 52: ...hree modules as follows 1 As described in Measuring Contact Resistance navigate to the parameter entry screen 2 Enter the module information Information Values outside the limits cannot be entered Values above the limits cannot be entered If an entered value is too low it will be displayed in red Fig 48 Enter Parameters screen ...

Page 53: ...Clicking Help makes it possible to display the automatically calculated parameter limits Information The entered parameter limits can be saved by clicking Save and can then be retrieved from the drop down menu 3 Click Next 4 Connect the positive red and negative black clamps as shown in the software ...

Page 54: ...ual Fig 50 Information Clicking Placement opens a view of the exact placement of the individual components Fig 51 5 Press and hold the button on the red test probe to start the measurement 6 Connect the positive red and negative black test probe ...

Page 55: ...he measurement is taken a tone is heard and another area can be measured 7 Click Report to view the test report If multiple measurements were taken the test report is expanded to include each additional measurement Click Edit to add comments 8 Click Save to save the record Fig 52 ...

Page 56: ...ith the IRP 120 IRP 120 54 User Manual 6 6 Displaying Device Data 1 Click Start Programs DiTEST DSS 2 Click Diagnostics IRP Fig 53 DSS Manager 3 A start screen appears Click Show Device Data Fig 54 Start screen ...

Page 57: ...IRP 120 Working with the IRP 120 User Manual 55 4 A start screen appears showing the device data Press F8 Next to go to the start screen Fig 55 Device data ...

Page 58: ...n the PC If necessary disconnect the IRP 120 from the USB connection on the PC wait a few seconds and then reconnect it Error message Solution description A timeout occurred Repeat the measurement Firmware not running run mode Quit the current measurement function and restart An overcurrent occurred Repeat the measurement An overvoltage occurred Repeat the measurement Error during self test Repeat...

Page 59: ...ert v WARNING Risk of death due to electric voltage Setting and maintenance work on open devices with live parts may only be performed by specialists who are trained in this area and who are aware of the associated dangers v WARNING Risk of death due to electric voltage The product may only be repaired by the supplier plant or by trained specialists 8 2 Cleaning the Device Risk of death due to ele...

Page 60: ...Ingress of liquids e g water oil acids etc Tampering third party intervention e g repairs performed by unauthorized individuals Incorrect operation e g cleaning with compressed air Incorrect storage maintenance and care e g cleaning the device with solvent based cleaning agents 9 2 Replacement or Loaned Devices The agreements with your supplier apply The effective date of the warranty is the date ...

Page 61: ...ithstand transient overvoltages of up to 4000 V according to CAT II 600 V or CAT III 300 V respectively Risk of death due to electric voltage The IRP 120 is not suitable for measurements on the supply mains The IRP 120 is only suitable for measuring DC voltages The battery modules must not be connected to a charger during the measurement For a correct measurement the battery must be disconnected f...

Page 62: ...nsation 4000 m 20 to 55 C at max 20 C 10 to 80 no condensation Electrical protection Safety regulations Measuring device EN 61010 1 EN 61010 2 30 EN 61010 031 Garage equipment UL 201 Protection class II Pollution degree II Overvoltage category CAT II 600 V CAT III 300 V Accuracy Contact resistance 40 A Accuracy 2 µΩ Resolution 0 1 µΩ 20 A Accuracy 4 µΩ Resolution 0 2 µΩ Internal resistance 40 A Ac...

Page 63: ...Two cables with Kelvin clamps for connection to the module connectors A cable with test probes for measurement at the battery modules or the contacts Disposal This AVL DiTEST product is a high quality electrical and electronic device that should not be disposed of with household waste During disposal it is essential to comply with local legal requirements ...

Page 64: ...ing on battery and contact type 11 Index A Assembly 10 C CAT Overvoltage Categories 59 Cleaning the device 57 Commissioning 15 Current Clamp Cable 12 D Displaying Device Data 54 E Error messages 56 G General description 3 H Hardware 15 I IMPORTANT SAFETY INSTRUCTIONS 6 In the event of damage 58 L LEDs 11 M Maintenance and Care 57 Measuring technology 62 N New devices 58 O Operating data 60 Overvie...

Page 65: ...Index IRP 120 User Manual 63 T Technical data 59 Test probe cables 13 Troubleshooting 56 V Visual check 57 W Warranty 58 ...