BOSCH FSA 050 Hybrid Tester Instruction Manual

BOSCH FSA 050 Hybrid Tester Instruction Manual

Symbols used

In the documentation
Warning notices – Structure and meaning
Warning notices warn of dangers to the user or people in the vicinity. Warning notices also indicate the consequences of the hazard as well as preventive action. Warning notices have the following structure:

Warning
symbol
KEY WORD – Nature and source of hazard! Consequences of hazard in the event of failure to observe action and information given.
Hazard prevention action and information.

The key word indicates the likelihood of occurrence and the severity of the hazard in the event of nonobservance:

Symbols on the battery cover

 Danger: Avoid contact with live parts.
 This symbol appears on the LCD during insulation analysis to warn users of hazardous voltage at the measurement leads. Always wait until the voltage has been discharged down to a safe level. Never exceed the interference voltage detection limit value.
 Devices fully protected by double insulation (class II).
 Devices which satisfy the relevant EC directives.
 Devices which satisfy “C mark” requirements.
 Maximum input voltage 600 V TRMS

Disposal
 Dispose of used electrical and electronic devices, including cables, accessories and batteries, separately from household waste.

User information

Important notes
Important information on copyright, liability and warranty provisions, as well as on equipment usersand company obligations, can be found in the separate manual “Important notes on and safety instructions for Bosch Test Equipment”. These instructions must be carefully studied prior to start-up, connection and operation of the FSA 050 and must always be heeded.

Safety instructions
All the pertinent safety instructions can be found in the separate manual “Important notes on and safety instructions for Bosch Test Equipment”. These instructions must be carefully studied prior to startup, connection and operation of the FSA 050 and must always be heeded.

EC Declaration of Conformity
FSA 050 bears the CE mark in accordance with the applicable EC Directives. The EC Declaration of Conformity is available for download as Adobe PDF document from http://downloads.bosch-automotive.com.

Electromagnetic compatibility (EMC)
FSA 050 satisfies the criteria of the European Directive EMC 2014/30/EU. This device is not intended for use within residential areas and cannot provide sufficient protection in such environments.

Measuring category
FSA 050 complies with the general safety requirements for electrical testers, measuring instruments and accessories in EN 61010-1 and EN 61010-2-033. FSA 050 and the terminal blocks and measurement cables supplied are designed for test and measurement circuits of Category IV (CAT IV) up to 600 V.

RED (Radio Equipment Directive)
Robert Bosch GmbH hereby declares that the radio equipment type FSA 050 conforms to the European Directive RED 2014/53/EU. The complete text of the EU declaration of conformity is available from the following web address: http://www.downloads.bosch-automotive.com

Wireless connections
Users of wireless systems are responsible for compliance with the applicable directives and restrictions in the country concerned. A “wireless system” in the sense of the European Directive RED 2014/53/EU (Radio Equipment Directive) is an electrical or electronic product (component) that transmits and/or receives radio waves as permitted for the purpose of wireless communication and/or radiolocation.

WLAN and Bluetooth instructions can be found in the separate instructions “Data protection, data security, wireless connections”.
http://mediathek.bosch-automotive.com/files/common/documents/1689/989393.pdf

Bluetooth
Bluetooth USB adapter
The Bluetooth USB adapter included in the scope of delivery is inserted into the PC/laptop and provides a radio link to components of FSA 050 capable of wireless communication.

Troubleshooting
i In the event of problems with the Bluetooth radio link, refer to the information in the separate instruction “Bluetooth USB Adapter”.
http://mediathek.bosch-automotive.com/files/bosch_wa/989/277.pdf

Information on Bosch Connected Repair
The “Bosch Connected Repair” software (CoRe) makes it possible to exchange customer and vehicle information as well as protocols in the workshop. For this, the testers (CoRe clients) are connected to a central computer (CoRe server) via the computer network. Related documents: Current overview of products supporting
Bosch Connected Repair:
http://mediathek.bosch-automotive.com/files/common/documents/1689/989386.pdf
Notes on system requirements, installation and other information on Bosch Connected Repair:
http://mediathek.bosch-automotive.com/files/common/documents/1689/989372.pdf

Important notes on operation of the FSA 050

Before using the FSA 050 it is essential to carefully study the safety instructions and warning notices. The FSA 050 is only to be operated by appropriately qualified personnel. Users must have a certificate of qualification for working with highvoltage systems.

• The FSA 050 may not be used while driving avehicle.
• The circuit to be tested must be switched off, deenergized, safely disconnected from the mains and proven to be deenergized before making the test connections for insulation analysis and continuity measurement.
• Avoid contact with circuit connections and exposed conductive parts, as well as other metal parts of devices during testing.
• After insulation analysis, the capacitive circuits must be allowed to discharge before disconnecting the measurement leads.
• The FSA 050 is not to be used if damaged.
• All measurement leads, remote sensors and terminals must be in a good, clean condition with intact insulation (no breaks or cracks). Measurements are only to be performed using the measurement leads and remote sensors included in the scope of delivery.
• When testing, take care to keep hands behind the protective covering of the measurement leads/ remote sensor/terminals.
• The authorities responsible for electrical safety in certain countries may require the use of measurement leads with fuse protection for taking voltage measurements on high-voltage systems.
• Spare fuses must be of the correct type and have the appropriate rating. Fuses with incorrect ratings could be a safety risk and cause damage to the FSA 050 in the event of overload.
• The battery cover must be properly attached when taking measurements.
• Users of the FSA 050 are reminded that the work safety legislation of the country concerned demands the performance of a valid risk assessment for all electrical work to permit identification of potential sources of electrical hazards and to reduce the likelihood of injuries resulting from electric shocks (in the case of unintentional short circuits for example). If such assessment reveals a significant risk, it may be appropriate to use measurement leads with fuse protection.

Product description

Usage
FSA 050 can either communicate via Bluetooth with computer that has FSA 7xx/500 software (CompacSoft[plus]) installed or be used as a standalone device. The FSA 050 is designed for the performance of insulation analysis on electric/hybrid vehicles. Voltage, capacitance and resistance can also be measured.

Prerequisites for operation with CompacSoft[plus]
Computer with operating system Windows 8 or Windows 10 and at least one vacant USB interface for the Bluetooth USB adapter. The current version of CompacSoft[plus] must be installed on the computer.
The FSA 050 has a Bluetooth transmission power of 10 mW (Class 2) ex works. The Bluetooth class can only be changed using the CompacSoft[plus] software.

Description of device

1. Red/black measurement leads
2. Red/black terminals
3. Remote sensor with test/zeroing button (TEST)
4. LCD
5. Function keys
6. Rotary switch for measurement functions
7. Rubber cover

Remote sensor
The remote sensor can be used instead of the red measurement lead. For insulation analysis, on the remote sensor has the same function as on the FSA 050. The resistance of the black measurement lead and the remote sensor can be zeroed for resistance measurement (Ω).

Insulation analysis procedure with remote sensor:

1. Connect the black measurement lead to the black negative socket of the FSA 050.
2. Connect the remote sensor to the 3-pin red positive socket of the FSA 050 (instead of the red measurement lead).
3. Connect the black measurement lead and the remote sensor to the circuit to be tested.
4. Select the correct range (50 V, 100 V, 250 V, 500 V or 1kV).
5. Press and hold on the remote sensor. ? Insulation analysis is performed.
6. To terminate insulation analysis, release on the remote sensor.

**Rotary switch/buttons

**

1. TEST (test/zeroing button)
2. /OK (lock/confirmation button)
3. Voltage measurement range
4. Rotary switch
5. Display(RCL)/Deletion(DEL) or data transfer(SND)1) of results saved
6. SETUP menu
7. Capacitance measurement range
8. Resistance measurement range
9. Continuity measurement range
10. Off switch (OFF)
11. Insulation measurement ranges

Function keys

1. STORE (save measurement result or selection key in SETUP menu)
2. DAR/PI/t or  (insulation analysis or selection key for stored measured values)
3. μA/s/V or  (display of amps, seconds or volts or selection key for stored measured values)
4. Continue (selection key in SETUP menu) or Status display (FSA/STA) in the measuring ranges
5. Buzzer on/off
6. Background illumination on/off
7. TRMS or DC

LCD background illumination can be selected when the FSA 050 is switched on (fig. 3, pos. 6). The background illumination goes out automatically after 20 seconds.

The buzzer (fig. 3, pos. 5) can be activated for continuity measurement. The symbol appears on the LCD (fig. 5, pos. 4).

Connection panel

1. Connection socket (–) for black measurement lead
2. Connection socket (+) for red measurement lead
3. Sockets (+) for remote sensor

LCD

1. Continuity measurement symbol
2. Digital auxiliary display
3. Auxiliary display units
4. Buzzer on
5. Battery charge indicator
6. Analog display
7. TRMS symbol (AC)
8. Main display units
9. Digital main display for measured value and status (FSA/STA)
10. Symbol for zeroing of measurement leads
11. Range overshoot symbol
12. Defective fuse symbol
13. Insulation analysis symbol (test voltage applied)
14. Lock symbol (insulation analysis)

Battery charge indicator
The current charge of the batteries is always indicated on the LCD (fig. 5, pos. 5). The number of bars shows the charge of the batteries in percent (fig. 6).

Rechargeable NiMH or NiCAD batteries indicate a lower charge than alkaline cell batteries. As a result, the charge indicator may abruptly switch to 0 % just before becoming flat.

Defective fuse symbol
The fuse in the FSA 050 must always have the correct rating – 500 mA (FF). The defective fuse symbol (fig. 5, pos. 12) flashes on the LCD if the internal fuse of the FSA 050 has blown due to overload. The fuse rating is indicated on the rating plate of the FSA 050.

Bluetooth USB adapter
Only the Bluetooth USB adapter included in the scope of delivery provides a radio link with the FSA 500/ FSA 7xx. It is plugged into the computer. The flashing LED shows that it is ready for operation.

Operation

The following description relates primarily to usage of the FSA 050 as a stand-alone unit. Bluetooth operation of the FSA 050 is described in the Online Help of the CompacSoft[plus] software. Installation of the CompacSoft[plus] software on a computer is described in sec. 5.13.
If the FSA status is set in the SETUP menu, FSA 050 blocks the insulation test and the display/deletion of the stored results in Stand-alone mode.

SETUP menu
The SETUP menu enables users to set values for use with the various FSA 050 functions. In the following table, the symbols and their significance are described in the order in which they are displayed.

SETUP – Setting status

1. Set the rotary switch to (fig. 2, pos. 6). ? The firmware version of the FSA 050 is displayed for four seconds and then ? The status of the FSA 050 (FSA or STA).
2. Press (fig. 2, pos. 1) for approx. two seconds. ? The status of the FSA 050 changes. ? The buzzer sounds briefly. ? The lock symbol  on the LCD flashes.
3. Briefly pressing changes the status (FSA/ STA) of the FSA 050.
4. Press </OK> to store the desired value (fig. 2, pos. 2). The desired value has been stored when the lock symbol  disappears from the LCD.

SETUP – Setting values

1. Set the rotary switch to . ? The firmware version of the FSA 050 is displayed for four seconds and then ? The status of the FSA 050 (FSA or STA).
2. Briefly press once. ? The first symbol and its value are displayed (bU2).
3. The next symbol is displayed by briefly pressing once.
4. Keep briefly pressing until the display shows the symbol for which the value is to be altered.
5. Press for roughly one second until the lock symbol  on the LCD flashes.
6. Keep briefly pressing until the desired value is displayed.

Preparation for measurement
With the exception of the voltage measurement range, the FSA 050 is intended for use on isolated, deenergized circuits. Before taking measurements, employ reliable means to ensure that the circuit to be tested has been completely disconnected from the power supply and reliably isolated.

Insertion of batteries
The FSA 050 is supplied without any batteries fitted.

1. Switch off the FSA 050. Remove the measurement leads and rubber cover (fig. 1, pos. 7).

2. Remove the battery cover screws (2x) and detach the battery cover.

3. Insert the batteries supplied, taking care to ensure correct polarity.
   Always fit five new batteries. When replacing, use the battery types 5 x IEC LR6 (AA, MN1500, HP7, AM3 R6HP) alkaline or rechargeable NiMH.

4. Re-attach the battery cover and secure with the screws.

5. Re-attach the rubber cover.

If correct polarity is not ensured on fitting the batteries, the FSA 050 may be damaged. If the battery charge indicator does not show any fully charged batteries after battery replacement, one battery may have been fitted with incorrect polarity. The FSA 050 is not to be switched on or connected to the measurement leads with the battery cover detached and the batteries inserted.
Refer to Section 6.1 with regard to flat batteries.

Checking measurement leads
Functional test

• Before using the FSA 050, always visually inspect the measurement leads, the remote sensor and the terminals to make sure the insulation is fully intact.
• Short-circuit the measurement leads to check their continuity (in the resistance measurement range Ω). The resistance of the shorted measurement leads should be less than 1.0 Ω.

Safety information
DANGER – Risk of electric shock from high DC voltages during insulation analysis.
Electric shocks resulting from contact with live parts can cause injuries or heart failure or even be fatal. As long as is locked in pressed position during insulation analysis, hazardous voltages may occur at any time in the insulation analysis area.

• Insulation analysis on hybrid vehicles, electric vehicles or equipment is only to be performed by trained power systems engineers.
• Avoid contact with live parts when performing insulation analysis.
• Take extreme care when measuring voltages above 30 V, particularly on highvoltage systems.

Measuring voltages and frequencies (High voltage analysis)
The voltage to be measured must not exceed a value of 600 V between phase and ground or between phase and phase.

1. Set the rotary switch to “V” (fig. 2, pos. 3).
2. Connect the measurement leads to the circuit to be tested. i When the FSA 050 is switched on, the TRMS function is set as standard. permits switching between the TRMS function and the DC function. ” The voltage and frequency are displayed (with the TRMS function).

Insulation analysis
DANGER – Risk of electric shock from high DC voltages during insulation analysis. Electric shocks resulting from contact with live parts can cause injuries or heart failure or even be fatal.

• Insulation analysis on hybrid vehicles, electric vehicles or equipment is only tobe performed by trained power systems engineers.
• Avoid contact with live parts when performing insulation analysis.

Depending on the interference voltage detection limit value set for insulation analysis (refer to Section 5.1), implementation of insulation analysis by the FSA 050 may be inhibited on exceeding the limit value to guard against damage to the device. The supply voltage applied is displayed. Voltages above the set limit value are indicated by the buzzer.

Automatic discharge
After performing insulation analysis, capacitive circuits are discharged automatically on releasing .

Before connecting the measurement leads, the circuit to be tested must be fully discharged and reliably isolated. Therefore, a voltage measurement should always be carried out before insulation analysis!

During insulation analysis, the symbol flashes on the LCD as long as the test voltage is being applied to the circuit to be checked.

Standard insulation analysis

1. Connect the measurement leads or the remote sensor to the circuit to be tested.
2. Set the rotary switch to the correct position (fig. 2, pos. 11) (50V, 100V, 250V, 500V or 1kV). ? ln5 appears on the LCD.
3. To start insulation analysis, press and hold (fig. 2, pos. 1). ? The insulation resistance value is displayed in both analog and digital form, together with the actual test voltage value.

i With pressed, the insulation analysis can be extended as required by additionally pressing </OK> (fig. 2, pos. 2). The lock symbol  appears and can be released. Press or </OK> again to cancel the lock.

Decommissioning

Change of location

• If the FSA 050 is passed on, all the documentation included in the scope of delivery must be handed over together with the unit.
• The FSA 050 is only ever to be transported in the original or equivalent packaging.
• Unplug the electrical connection.
• Heed the notes on initial commissioning.

Disposal and scrapping
FSA 050, accessories and packaging should be sorted for environmental-friendly recycling.

• Do not dispose FSA 050 into household waste.

Only for EC countries:
 The FSA 050 is subject to the European directive 2012/19/EC (WEEE). Dispose of used electrical and electronic devices, including cables, accessories and batteries, separately from household waste.

• Make use of the local return and collection systems for disposal.
• Proper disposal of FSA 050 prevents environmental pollution and possible health hazards.

Technical data

All the values given are referenced to a temperature of 20 °C.

Insulation analysis
The specifications only apply in conjunction with the remote sensor and the measurement leads contained in the scope of delivery

Range Accuracy
1000 V 200 GΩ ±3 % ±2 positions ±0.2 % per GΩ
500 V 100 GΩ ±3 % ±2 positions ±0.4 % per GΩ
250 V 50 GΩ ±3 % ±2 positions ±0.8 % per GΩ
100 V 20 GΩ ±3 % ±2 positions ±2.0 % per GΩ
50 V 10 GΩ ±3 % ±2 positions ±4.0 % per GΩ

Voltage measurement

• 0 to 600 V DC ± 2% ± 2 positions
• 10 mV to 600 V TRMS sinusoidal (40–400 Hz) ±2% ±2 positions
• 0 to 1000 V on the analog scale
• Non-specified input level 0–10 mV (40–400 Hz)
• Additional specifications apply to non-sinusoidal curves:
  • ±3 % ±2 positions / 101 mV – 600 V TRMS and
  • ±8 % ±2 positions / 10 mV – 100 mV TRMS

Standard voltmeter

• Operates at >25 V AC or DC in any range except OFF
• Frequency:
  40–450 Hz (40 Hz–99.9 Hz) ±0.5 % ±1 position (100 Hz to 450 Hz)

Intrinsic error and operating error

The intrinsic error is the maximum inaccuracy of the FSA 050 under ideal conditions, whereas the operating error is the maximum inaccuracy with allowance for battery voltage, temperature, interference, system voltage and system frequency.

Intrinsic error
Refer to Section 8 -Technical data.

Operating error

Function Specification
Insulation range ±15 % ±2 positions
Continuity range ±26 % ±2 positions
Resistance range ±12 % ±2 positions
Voltage range ±10 % ±2 positions
Capacitance range ±18 % ±2 positions
Frequency range ±5 % ±2 positions

References

• Media Library - Bosch Automotive Service Solutions
• Home | Mobility Aftermarket

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