USER MANUAL
AVL DITEST AUX 2000
Ident number:
Revision:
Issue:
AT7726E
02
11 / 2016
Data may change without notice.
All data valid at the time of printing
FUTURE SOLUTIONS FOR TODAY
AVL DiTEST GmbH
Alte Poststrasse 156
A-8020 Graz / AUSTRIA
Tel: +43 316 787-0
Fax: +43 316 787-1460
ditest@avl.com
www.avlditest.com
Copyright © 2016 AVL DiTEST GMBH, all rights reserved.
The content of this publication may not be reproduced in any way or forwarded to third
parties, either in part or in full, without the prior written consent of AVL DiTEST. This
publication was created with due care such that AVL DiTEST is not liable for any remaining
errors or omissions or for any damages arising therefrom.
AVL DiTEST AUX 2000
Warning and Safety Notices
Warning and Safety Notices
This device manual contains important warning and safety notices that must be
observed by the user.
The product is intended only for the highly specific use described in the user manual.
The most important prerequisites and safety measures for the use and operation of
the product are also described to ensure faultless operation.
No warranty can be given and no liability is assumed for applications beyond the
described use, irrespective of observance of the necessary prerequisites and safety
measures.
The product may only be used and operated by personnel who, based on their
qualifications, are capable of adhering to the necessary safety measures during use
and operation. Only accessories and consumables supplied by AVL DiTEST or
approved by AVL DiTEST may be used. The measurement results obtained from
the product in question depend not only on correct functioning of the product, but
also on a series of general conditions. The results delivered by the product must
therefore be evaluated by a specialist (e.g. plausibility check) before further
measures are taken on the basis of a delivered measurement.
Settings and maintenance work on open devices while still live may only be
performed by trained specialists who are aware of the associated danger.
The product may only be repaired in the factory of origin or by specialists specifically
trained to perform such repair.
When using the product, it must be ensured by a specialist that the test object or
test system is not brought into any operational state that could result in damage to
goods or endangerment of people.
User Manual
I
Warning and Safety Notices
II
AVL DiTEST AUX 2000
User Manual
AVL DiTEST AUX 2000
Summarized Safety Notices
Summarized Safety Notices
DANGER
Danger to life by electric potential on vehicles with high voltage systems
Deadly high voltages are present on the HV energy store (HV battery) and on parts connected to it!
Make sure no-one can come into contact with the connections on the HV battery, connecting
cables of the HV battery or other parts under high voltage!
WARNING
Danger to life by electric potential on the ignition system
The ignition system carries a deadly high voltage!
Do not touch the ignition system while the motor is running!
WARNING
Danger to life by electric potential on vehicles with Xenon light
A lighting system that uses a xenon light carries a deadly high voltage!
Do not touch the components of the xenon light while the lighting is turned on!
WARNING
Danger from harmful or irritating substances
When performing measurements on the running motor in closed rooms (workshops, test halls,
etc.), extract the vehicle exhaust gases and ventilate the rooms thoroughly!
WARNING
Risk of burns from hot parts
Measurements must be performed at normal motor operating temperature or according to the test
specification! Do not touch hot parts such as the motor, motor components or any of the entire
exhaust system! Use cooling fans if necessary!
User Manual
III
Summarized Safety Notices
AVL DiTEST AUX 2000
WARNING
Risk of injury from rotating parts
Only ever perform work in the engine bay while the motor is not running and the ignition is turned
off!
Do not touch any rotating parts such as alternator, radiator fan or their drives (e.g. drive belts)!
Make sure measurement cables are laid safely while the motor is running!
WARNING
Risk of injury from unsecured vehicle
Engage the handbrake or shift the gearshift to P (on automatics)!
Adequately secure the vehicle against rolling!
WARNING
Risk of explosions due to pyrotechnical setups and restraint systems
Testing and assembly work may only be performed by trained personnel!
Never test the igniter with a multimeter!
Only perform system tests with approved testing equipment!
Disconnect the battery when working on the airbag system!
When reconnecting the battery, the ignition must be turned off and there must be no person inside
the vehicle.
Always store the airbag unit with the discharge side facing upwards or according to the storage
specifications!
Never leave the airbag unit lying around unattended!
Protect the airbag unit against flying sparks, open fire and temperatures above 100°C!
Do not transport the airbag unit in the passenger space!
Do not allow the airbag unit to come into contact with oil, grease or cleaning agents!
An airbag unit that has been dropped from a height greater than 0.5 m must be renewed!
Dispose of untriggered airbag units!
Do not open or repair the airbag unit!
NOTICE
When maintaining the cut-off speed of diesel engines, observe the applicable manufacturer’s
specifications!
NOTICE
Always turn off the ignition before connecting or disconnecting the OBD connector or the various
AVL DiTEST vehicle adapters!
IV
User Manual
AVL DiTEST AUX 2000
Contents
Contents
Warning and Safety Notices ........................................................................ I
Summarized Safety Notices ....................................................................... III
1
General ........................................................................................... 1-1
1.1
1.2
1.3
1.4
1.5
2
Commissioning .............................................................................. 2-1
2.1
2.2
2.3
2.4
2.5
3
AVL DITEST AUX 2000 Power Supply ......................................................................... 2-1
AVL DITEST AUX 2000 - PC .......................................................................................... 2-3
Combo Sensor and Oil Temperature Sensor .............................................................. 2-4
AVL DiSpeed 492 ........................................................................................................... 2-5
Firmware Update ............................................................................................................ 2-6
Adapting Cables and Probes ........................................................ 3-1
3.1
3.2
4
General Description ....................................................................................................... 1-1
AVL DITEST AUX 2000 Front View ............................................................................... 1-2
AVL DITEST AUX 2000 Rear and Side View ................................................................ 1-3
AVL DiSpeed intern ....................................................................................................... 1-4
AVL DiSpeed 492 ........................................................................................................... 1-4
Measuring Speed ........................................................................................................... 3-1
3.1.1 Function Indications of the Status LED ................................................................. 3-4
Oil/Coolant Temperature Measurement....................................................................... 3-5
3.2.1 Oil Temperature Sensor ........................................................................................ 3-5
Maintenance ................................................................................... 4-1
4.1
4.2
4.3
AVL DITEST AUX 2000 .................................................................................................. 4-1
Oil Temperature Sensor ................................................................................................ 4-1
Combo sensor ................................................................................................................ 4-1
5
Technical Data ............................................................................... 5-1
6
Index .............................................................................................. 6-1
User Manual
V
Contents
VI
AVL DiTEST AUX 2000
User Manual
AVL DiTEST AUX 2000
1
General
1.1
General Description
General
The AVL DiTEST AUX 2000 measures oil coolant temperature and speed. It is powered by an
external desktop power supply or through the AVL DiTEST Gas 1000.
AVL DiTEST AUX 2000 connects to a PC via USB cable. Alternatively, it can be connected over a
wireless Bluetooth connection.
The module features inputs for the following auxiliary variables:

Temperature sensor (oil coolant measurement)

Combo sensor (speed measurement)

Connection for AVL DiSpeed 492 (speed measurement)
PC
Wireless
Bluetooth
connection
(optional)
USB cable
AVL DiTEST AUX 2000 interfaces
Temperature sensor
(oil coolant measurement)
AVL DiSpeed 492
(speed measurement)
AVL Combo Sensor
(speed measurement)
Fig. 1-1
User Manual
1-1
General
1.2
AVL DiTEST AUX 2000
AVL DITEST AUX 2000 Front View
1
2
3
4
Fig. 1-2
1
2
3
4
1-2
Bluetooth antenna (optional)
Socket for temperature sensor, see also chapter 3.1.1.
Socket for external AVL DiSpeed 492, see also chapter 1.5 or
the AVL DiSpeed 492 User Manual
Socket for combo sensor, see also chapter 3.2.
User Manual
AVL DiTEST AUX 2000
1.3
General
AVL DITEST AUX 2000 Rear and Side View
1
2
3
4
Fig. 1-3
1
2
3
4
Socket for power supply (external desktop power supply or connector cable to AVL Gas 1000)
USB port for connection to PC
External desktop power supply
Mains cable
User Manual
1-3
General
1.4
AVL DiTEST AUX 2000
AVL DiSpeed intern
Universal speed measurement for gasoline and diesel engines







1.5
Built into AVL AUX 2000
No need to set the number of cylinders
For gasoline and diesel engines, with best coverage
For stationary and dynamic speed measurements
Automatic self-calibration and function monitoring
Easy attachment with integrated permanent magnet
Unique direct signal acquisition
AVL DiSpeed 492
Universal speed measurement for gasoline and diesel engines

No need to set the number of cylinders

For gasoline and diesel engines, with best coverage

For stationary and dynamic speed measurements

Automatic self-calibration and function monitoring

Easy attachment with integrated permanent magnet

Unique direct signal acquisition
Also observe the AVL DiSpeed 492 User Manual.
Fig. 1-4
1-4
User Manual
AVL DiTEST AUX 2000
Commissioning
2
Commissioning
2.1
AVL DITEST AUX 2000 Power Supply
Connect the AVL DiTEST AUX 2000 (1) to the mains using the external desktop power supply
BV7559 (2) as shown.
(2) Ext. desktop
power supply
BV7559
(1) AVL DiTEST AUX 2000
BO7788 (without BT)
BO7795 (with BT)
Fig. 2-1
User Manual
2-1
Commissioning
AVL DiTEST AUX 2000
If you are using an AVL Gas 1000 (4), then you can connect the power through the AVL Gas 1000.
In this case, use the BV8039 (4) cable to connect the AVL DiTEST AUX 2000 (1) to the AVL Gas
1000 as shown. (Then you do not need the ext. desktop power supply BV7559 for AVL DiTEST AUX
2000).
Ext. desktop power supply
BV7559
(4) AVL Gas 1000 BO7720
(3) Cable BV8039
(1) AVL DiTEST AUX 2000
BO7788 (without BT)
BO7795 (with BT)
Fig. 2-2
2-2
User Manual
AVL DiTEST AUX 2000
2.2
Commissioning
AVL DITEST AUX 2000 - PC
Insert the BO7146 (5) USB dongle into a free port on the PC (7).
Use the EX7030 (6) cable to connect the AVL DiTEST AUX 2000 (1) to the PC (7) as shown.
The AVL DiTEST AUX 2000 can also be connected to the PC over a wireless Bluetooth connection.
In this case, insert the Bluetooth stick (8) into a free USB port on the PC (7) and screw the Bluetooth
antenna
(9)
onto
the
AVL
DiTEST
AUX
2000
(1).
Make the necessary settings in the AVL DSS software.
(5) USBDongle
BO7146
(7) PC
(6) USB cable EX7030
(8) Bluetooth stick
(2) AVL DiTEST
AUX 2000
BO7788 (without BT)
BO7795 (with BT)
(9) Bluetooth antenna
(optional)
Fig. 2-3
User Manual
2-3
Commissioning
2.3
AVL DiTEST AUX 2000
Combo Sensor and Oil Temperature Sensor
Connect the BO2338 (10) combo sensor and the BV7007 (11) oil temperature sensor to the
AVL DiTEST AUX 2000 (1) as shown.
(1) AVL DiTEST AUX 2000
BO7788 (without BT)
BO7795 (with BT)
(10) AVL Combo sensor BO2338
(11) Oil temperature sensor BV 7007
Abb. 2-4
2-4
User Manual
AVL DiTEST AUX 2000
2.4
Commissioning
AVL DiSpeed 492
Information
If you have an AVL DiSpeed 492 BV7232 (12), then this can be connected to the AVL DiTEST AUX
2000 (1) using the BV2111 (13) cable as shown.
(1) AVL DiTEST AUX 2000
BO7788 (without BT)
BO7795 (with BT)
(13) Connector cable BV2111
(12) AVL DiSpeed 492 BO7232
AVL Kombisensor BO2338
Fig. 2-5
User Manual
2-5
Commissioning
2.5
AVL DiTEST AUX 2000
Firmware Update
To update the AVL DiTEST AUX 2000 firmware, it must be connected to the PC by USB cable, or a
wireless Bluetooth connection must be established with the PC. Refer to chapter 2.2 “AVL DITEST
AUX 2000 - PC” for this.
Refer to your software documentation about the exact procedure for updating the firmware.
2-6
User Manual
AVL DiTEST AUX 2000
Adapting Cables and Probes
3
Adapting Cables and Probes
3.1
Measuring Speed
Connect the AVL Combo Sensor as shown.
The AVL Combo Sensor has a magnetic foot, and must therefore be attached to an iron part of the
engine.
The best speed recording results are obtained when the engine vibrations are not dampened by
rubber-cushioned parts between the engine and attachment point (engine suspension).
You can attach the AVL Combo Sensor while the engine is off or idling. As soon as the engine starts
to idle, an LED on the Combo Sensor gives feedback as to whether the chosen attachment point is
suitable or not (see chapter. 3.2.1).
NOTICE
If the AVL Combo Sensor is attached to the idling engine:

Observe the warning notices at the beginning of the user manual

The LED on the AVL Combo Sensor will show after 3 to 10 seconds
whether the AVL DiTEST AUX 2000 has recorded the speed or not
The following engine parts are examples of where you can connect the AVL Combo Sensor:
Bolt heads:
Fig. 3-1
Fig. 3-2
Flat sheet metal parts Mounting brackets:
(crane eyes for engine mounting):
Fig. 3-3
Fig. 3-4
User Manual
3-1
Adapting Cables and Probes
AVL DiTEST AUX 2000
Oil drain plug:
Brake lever holder (motorcycle):
Fig. 3-5
Fig. 3-6
Exhaust clamp, exhaust mounting points (be cautious of heat development!):
Fig. 3-7
Fig. 3-1
Heat shields and aggregate fastenings:
Fig. 3-9
3-2
Fig. 3-10
User Manual
AVL DiTEST AUX 2000
Adapting Cables and Probes
Hollow bolt of rear axle suspension mount:
Fig. 3-11
Fig. 3-12
Bolt on brake hose fastening of rear brake cylinder:
Fig. 3-2
User Manual
Fig. 3-14
3-3
Adapting Cables and Probes
AVL DiTEST AUX 2000
3.1.1 Function Indications of the Status LED
The AVL Combo Sensor indicates various functions by an LED (red/yellow/green).
LEDs
Meaning
Green LED blinks twice  2-stroke motorcycle mode is selected
Green LED blinks four
times
 4-stroke motorcycle mode is selected
Red LED lights
 Self-test okay
 No speed signal recognized
Red LED blinks when
you switch on the AVL
DiTEST AUX 2000
 The self-test has detected an error.
Please note the number of blink signals and contact the responsible
AVL DiTEST Service.
Red and green LED
light
(red/green LED on
Combo Sensor lights
yellow)
 Idle speed recognized (first calibration point)
Green LED lights
 The AVL DiTEST AUX 2000 has recognized the high speed (second
calibration point)
The idle speed is typically recognized within 3 to maximum 10
seconds upon attaching the sensor
If no speed signal is recognized during this time, then attach the AVL
Combo Sensor in a different place.
 Stationary speed values are now measured.
With this status, the AVL DiTEST AUX 2000 is also calibrated for
dynamic speed measurements
 Now both stationary and dynamic measurements can be performed.
3-4
User Manual
AVL DiTEST AUX 2000
3.2
Adapting Cables and Probes
Oil/Coolant Temperature Measurement
3.2.1 Oil Temperature Sensor
With gasoline engines, make sure the oil temperature probe sealer seals tightly (leak air onto the
oil dipstick influences the control circuit).
NOTICE
Before inserting the oil temperature sensor, dry the rubber cone on the probe and the counterpart
on the engine.
You must adjust the length of the oil temperature probe to the length of the original dipstick.
An inadequate adjustment could cause damage to the engine and the oil temperature sensor!
With OBD vehicles, it is not necessary to measure the oil temperature using an oil temperature probe.
The oil temperature is measured via the OBD connector of the vehicle.
User Manual
3-5
Adapting Cables and Probes
3-6
AVL DiTEST AUX 2000
User Manual
AVL DiTEST AUX 2000
4
Maintenance
4.1
AVL DITEST AUX 2000
Maintenance
The AVL DITEST AUX 2000 requires no special maintenance.
4.2
Oil Temperature Sensor
If necessary, make sure:

the plug contacts are not bent

oil temperature sensor is not polluted
4.3
Combo sensor
For the structure-borne sound to be measured correctly, the magnetic foot must be free of iron filings
and dirt. The airborne sound inlets on the top of the AVL combo sensor must also be free.
Cleaning the combo sensor:

with a mild cleaning product

with a jet of compressed air directed flat over the side of the sensor
NOTICE
Do not clean the airborne sound inlets with a sharp object, or you run the risk of damaging the
microphone!
Never direct a jet of compressed air straight at the top of the sensor – that would destroy the sealing
membrane and the microphone!
User Manual
4-1
Maintenance
4-2
AVL DiTEST AUX 2000
User Manual
AVL DiTEST AUX 2000
5
Technical Data
Technical Data
Housing:
Weight
Approx. 0.5 kg
Length
210 mm
Width
125 mm
Height
35 mm
Power supply from mains:
Mains voltage
12–24 VDC from ext. desktop power supply
(The device can also be powered through the
AVL Gas 1000)
Power:
Rated power
Approx. 5 VA power draw by AVL DiTEST AUX 2000
without connected AVL DiSpeed 492
Climatic conditions:
Ambient temperature
Operating temperature range
+ 0 to + 40 °C
Storage
− 20 to +55 °C
Relative air humidity
10 to 90 %, non-condensing
Measurement parameters:
Rev. speed
Diesel engines:
400–6000 min-1
Gasoline engines:
400–6000 min-1
Search range, idle:
400–6000 min-1
Search range, high rev. speed: 1700–6000 min-1
Oil temperature
-10 to 145 °C
Interfaces:
USB 2.0
PC connection
POWER SUPPLY
Connection of ext. desktop power supply or AVL Gas 1000
COMBO SENSOR
Connection of AVL combo sensor
REV. SPEED
Connection of AVL DiSpeed 492 (optional)
OIL TEMP
Oil temperature sensor (PT1000)
BLUETOOTH
(optional)
Bluetooth antenna connection;
– communication between AVL DiTEST AUX 2000 and PC
Subject to technical change.
User Manual
5-1
Technical Data
AVL DiTEST AUX 2000
Compliance:
AVL DiTEST AUX2000 complies with the following standards or
normative documents:
EN 61326-1:06 Electrical equipment for measurement,
control and laboratory use
EMC requirements
(Electrical equipment for measurement, control
and laboratory use. EMC requirements)
EN 61010-1:01 Safety requirements for electrical equipment
for measurement, control and laboratory use
(Safety requirements for electrical equipment
for measurement, control and laboratory use)
And thereby complies with the provisions of the following EU
Directives in their prevailing versions:
2004/108/EC
Electromagnetic compatibility
(Electromagnetic compatibility)
2006/95/EC
Low voltage directive
(Low voltage directive)
1999/5/EG (EC) Radio and telecommunications terminal
equipment
(Radio and telecommunications terminal
equipment – R&TTE)
Disposal:
This product of AVL DiTEST is a high-quality electrical and
electronic device that may not be disposed of in the household
waste.
5-2
User Manual
AVL DiTEST AUX 2000
6
Index
Index
A
Adapting Cables and Probes 3-1
AVL DiSpeed 492 1-4, 2-5
AVL DiSpeed intern 1-4
AVL DITEST AUX 2000 Front View 1-2
AVL DITEST AUX 2000 Rear and Side
View 1-3
AVL DITEST AUX 2000
Power Supply 2-1
O
Oil Temperature Sensor 3-5
S
Summarized Safety Notices III
W
Warning and Safety Notices I
C
Commissioning 2-1
Combo sensor 2-4
F
Function Indications of the Status LED
3-4
G
General 1-1
General Description 1-1
User Manual
6-1
Index
6-2
AVL DiTEST AUX 2000
User Manual
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