Hella Gutmann Mt-hv Solutions Instruction Manual

Text parts marked in this way indicate an imminent dangerous situation, which will lead to death or severe injuries if not avoided.

Text parts marked in this way indicate a possibly dangerous situation, which may lead to death or severe injuries if not avoided.

Text parts marked in this way indicate a possibly dangerous situation, which may lead to death or severe injuries if not avoided.

This symbol indicates dangerous electric voltage/high voltage.

These symbols indicate rotating parts.

This symbol indicates the risk of crushing limbs.

This symbol indicates a potential injury of the hand.

This symbol indicates a potential chemical burn.

All texts labeled IMPORTANT refer to a hazard in the device or environment. The advices or rather instructions stated here must therefore be observed by all means.

Texts marked with NOTICE contain important and helpful information. It is recommended to observe these texts.

This symbol indicates that the product must not be discarded as domestic waste.

The bar underneath the waste bin symbol indicates that the product has been put on the market after 13 August 2005.

This marking indicates that the user manual must always be read and always be available.

the MT-HV operating instructions and in the user documentation of the mega macs X. All the symbols on the MT-HV and the following measures and safety precautions shall also be observed.

•  Furthermore, pay attention to all general instructions from labour inspectorates, trade associations and vehicle manufacturers as well as all laws, legal ordinances and instructions which have to be commonly obeyed by a repair shop.

•  Protect the MT-HV and all connecting cables from hot parts.
•  Protect the MT-HV and all connecting cables from rotating parts.
• Regularly check all connecting cables/accessory parts for damage (destruction of the MT-HV due to short circuit).
•  Only used certified test prods and high-voltage test leads.
•    Regularly check the test prods and the high-voltage test leads for damage prior to every application (visual inspection).
•     Do not exceed the allowed operating and ambient temperatures.
•   Keep the MT-HV away from fluids such as water, oil or gasoline. The MT-HV is not waterproof.
•   Protect the MT-HV from strong impacts and do not drop it.
•   Immediately contact Hella Gutmann or a Hella Gutmann trading partner in case of any malfunctions of the MT-HV.

Very high voltages occur in electrical systems. Due to voltage flashover on damaged components, such as marten damage or touching live components, the risk of electric shock is likely. Voltage flashover can occur e.g. on the primary and secondary side of the ignition system, the connection to the vehicle, the lighting systems or the wiring harness with plug connections. Therefore regard the following:

•  Only use power supply cables with grounding contact.
•   Only use a checked or the attached power cord.
•  Always use the original cable set.
•    Do not exceed the voltage limits indicated on the connecting cables.
•    The voltage values to be measured must be shielded extra or even twice from dangerous line voltage. The voltage limits printed on the test leads must not be exceeded. Pay attention that the allowed measuring range is not exceeded when measuring positive and negative voltage at the same time.
•     Regularly check cables and adapters for damage.
•  Perform any assembly work such as the connection of the MT-HV to the vehicle or the replacement of components only when ignition is switched off.

•     Do not touch live components when the ignition is on.

•      Wear personal protective equipment when working on the battery.
•  Immediately rinse acid splashes from parts of the body or clothing thoroughly with water and consult a doctor instantly.
•  Instantly consult a doctor if you have aspirated acid vapor.

•  Protect vehicle against rolling away.
• Additionally, place the gear selector to park position in vehicles with automatic transmission.
• Deactivate the start/stop system to avoid an inadvertent engine startup.
•   Connect the MT-HV to the vehicle only when ignition is switched off.
•  Do not reach into rotating components when engine is running.
•   Do not run cables near rotating parts.
•    Check the high-voltage parts for damage.

Very high tensions occur on hybrid and electric vehicles. Due to voltage flashover on damaged components, such as marten damage or touching live components, the risk of electric shock is likely. High voltage at or in the vehicle can lead to death in case of inattention. Therefore regard the following:

• Only the following qualified employees are allowed to de-energize the high-voltage system:
•  High-voltage technician

Skilled electrician for predetermined operations – Hybrid or rather electric vehicles

•   Skilled electrician
• Place and attach warning signs and barriers.
• Check the high-voltage system and the high-voltage lines for damage (visual inspection!).
• De-energizing the high-voltage system:
•    Regard the manufacturer- and vehicle-specific regulations.
• Regard the vehicle manufacturer’s instructions.
• Securing the high-voltage system against re-activation:
•    Withdraw the ignition key and keep it safe.
• Keep the service disconnect plug in a safe place or secure the battery master switch against re-activation.
• Insulate the battery master switch, the plug connections etc. with dummy plugs, covering caps or insulating tape with the corresponding warning notice.
• Check the de-energized state with the MT-HV or another suitable and approved measuring tool. Even with disconnected high-voltage system, residual voltage can still be present.
• Ground and short-circuit the high-voltage system (necessary only if voltage is higher than 1000 V).
• Voltage below 1000 V: Cover the parts which are close to the system or which are energized e.

g. with insulating cloth, hoses or plastic coverings. Voltage higher than 1000 V: Cover the parts with insulating plates/protective panels specially developed for this purpose so that sufficient protection against contact to adjacent parts is ensured.

•   Regard the following before re-energizing the high-voltage system:
•  All tools and utilities are removed from the hybrid/electric vehicle.
•   Remove the grounding and short circuit of the high-voltage system. Do not touch any of the cables now.
• Attach the protective paneling that has been removed before.
• Remove the protective measures at the switching system.

1

MT-HV

1

Power adapter and power cord

1

Operating instructions

1

MT-HV

1

Power adapter and power cord

1

High-voltage test leads black/red

1

Operating instructions

1

MT-HV

1

Power adapter and power cord

1

High-voltage test leads black/red

1

MT 77

1

Black/blue test lead

Red/black test lead

1

Operating instructions

1

Connect the red high-voltage test lead here.

2

Connect the black high-voltage test lead here.

3

Insert another module (e.g. MT 77) into the module slot.

4

•   Use the unlocking button to unlock and remove the MT-HV.
• Use the unlocking button to check if the inserted module is properly inserted.

7

Connect a power adapter to the power supply socket to supply the MT-HV with voltage and to charge the internal battery.

8

This LED indicates if e.g. a high-voltage measurement process is active or if high voltage is applied to the test prods (e.g. in case of insulation resistance measurement).

The different status indications are explained in the section User Communication 

9

This LED indicates the various battery charging states.

The different battery status display are explained in the section User Communication 

10

This LED indicates that an update is in progress.

This LED indicates that the MT-HV is connected via Bluetooth®.

12

This LED indicates e.g. if the MT-HV is active or ready for operation.

The different status indications are explained in the section User Communication

Switch the MT-HV on and off with the ON/OFF button.

14 / 15

Connect the test leads to Scope 2 (CH2) here.

•     red = signal +

•     black = signal –

Connect the blue and the green clamp meter here.

17 / 18

Connect the test leads to Scope 1 (CH1) here.

•     blue = signal +

•     black = signal –

19

•     4-mm-test connection (safety connector) for manufacturer-specific test adapters

•     incl. function button to start or to confirm measurements

4-mm-test connection (safety connector) for manufacturer-specific test adapters

•     When the MT-HV is switched on and you briefly push ON/OFF, the green LED will flash several times until the MT-HV is shut down entirely.

Explanation of the battery status display:

more than 40 % of entire charge

•     The battery status indicator flashes green if the battery is being charged.

•     The status indicator is permanently green if the battery is fully charged.

20 % to 40 % of entire charge

20 % or less (charging required!)

•     The battery status indicator flashes red if battery charge is less than 10 %.

You can alternatively use the measurement module MT 56 for measuring voltage, current and resistance.

Danger to life due to electric voltage

It is a precondition for performing high-voltage measurements that the user has knowledge of automotive technology and is therefore aware of the sources of danger and risks in the workshop and on motor vehicles. An additional country-specific qualification is mandatory.

Danger of destruction of the MT-HV and/or the automotive electronics

•     Only used certified test prods and high-voltage test leads.

•     Check the test prods and the high-voltage test leads for damage prior to every application (visual inspection).

Danger to life due to electric voltage on vehicles with high-voltage systems

•     It is a precondition for performing high-voltage measurements that the user has knowledge of automotive technology and is therefore aware of the sources of danger and risks in the workshop and on motor vehicles. An additional country-specific qualification is mandatory.

•     Ensure, that the component to be evaluated is de-energized.

•     Pay attention not to touch connections and connecting cables of the high-voltage battery module.

•     Pay attention not to touch energized components.

The following image is an example.

The guidelines listed here are exclusively valid within the European Union.

Ambient temperature

Working range: 0 to 45 °C

Storage temperature: -10 to 60 °C

Measured variables of the HV modules

•     Potential equalization measurement

•     Insulation resistance measurement

•     Resistance measurement (service disconnect plug)

Interfaces

•     Bluetooth®

•     RJ45

Voltage

•     Resolution: 0.1 V

•     Precision: ± (1 % of reading + 2 digits)

Insulation resistance measurement

•     Test voltage: variably adjustable to 1000 V DC in steps of 10 V

•     Resolution: 0.1

•     Precision: ± (3 % of reading + 3 digits)

Resistance (service disconnect plug)

•     Resolution: 0.01 Ω

•     Measuring current: 200 mA

•     Precision: ± (2.5 % of reading + 4 digits)

Potential equalization measurement

•     Resolution: 0.01 Ω

•     Measuring current: 200 mA

•     Precision: ± (2.5 % of reading + 4 digits)

Red

•     Handpiece with function button

•     With 4 mm test connection for manufacturer-specific test adapters

•     incl. plug-on measuring probe

black

•     Handpiece

•     With 4 mm test connection for manufacturer-specific test adapters

•     incl. plug-on measuring probe

Ambient temperature

Working range: 0 to 45 °C

Storage temperature: -10 to 60 °C

Measured variables

•     Current (external clamp meter)

•     Resistance

•     Pressure (external LPD kit)

Interfaces

•     1x ST3 (12-pin)

•     1x module interface (USB) ST3 connections

•     6x communication

•     1x voltage inlet 10-15 V

•     1x voltage outlet +17 V

•     2x scope (+/-)

•     1x hardware detection (coding)

•     1x ground

Voltage

10 positions, 0.01 to 20 V/Div

•     Measurable voltage

max. 200 V

Current

• Blue clamp (CP 700)
•     Measuring range: ± 700 A
•    Current load: max. 25 mA
• Green clamp (CP 40)
•     Measurable current: -10 to 40 A
• Current load: max. 25 mA

Resistance

• Range: 6 positions, 1 Ohm/Div to 100 kOhm/Div
• Current output: 1 to 10 Ohm/250 µA, 10 to 100 Ohm/2.5 mA, 100 kOhm/25 µA, 1 MOhm/2.5 µA
• Measurable resistance: approx. 1 MOhm

Pressure (with LPD kit)

• Range: 4 positions, 0.2 to 2 bar/Div
• Measurable pressure: max. 60 bar