Volkswagen VAS 6910 Operating Manual

Operating manual V10.00

11/18

Module-Balancer VAS 6910

Content

SAFETY INSTRUCTIONS .......................................................... I

1 GENERAL INFORMATION ........................................... 1-1

1.1 General Notes ............................................................................................. 1-1

1.2 Safety Notes ................................................................................................ 1-2

1.3 Certificate of Calibration .............................................................................. 1-2

1.4 Designated Use ........................................................................................... 1-4

1.5 Associated Documents ................................................................................ 1-4

1.6 Field of application ....................................................................................... 1-4

2 COMPONENTS ............................................................. 2-1

2.1 VAS 6910 Adapter and transport box .......................................................... 2-1

2.2 VAS 6910 Module-Balancer ........................................................................ 2-6

2.3 Cable sets .................................................................................................. 2-12

2.3.1 USB-Cable (USB 2.0 Fischer to USB 2.0 B Rugged)

BV8139, VAS 611003, ASE 611 003 00 000 ................................ 2-12

2.3.2 USB-cable (USB 2.0 A to USB 2.0 B Rugged)

EX7069, VAS 611001 ASE 611 001 00 000 ................................ 2-12

2.3.3 Basic cable set Module adaption 1 (e-up!)

VAS 6910/10 ASE 447 240 00 000 .............................................. 2-13

2.3.4 Extension cable set Module adaption A (e-Golf)

VAS 6910/11 ASE 447 241 00 000 .............................................. 2-14

2.3.5 Basic cable set Module adaption 2 (PHEV)

VAS 6910/12A ASE 447 242 01 000 ........................................... 2-15

2.3.6 Basic cable set Module adaption 3 Adapter cable

Porsche G1 II & E2 II PHEV VAS 6910/13 ASE 447 243 00 000 2-16

2.3.7 Basic cable set Module adaption 4 (XL1)

VAS 6910/14 Purchase via r XL1 After Sales Volkswagen AG .... 2-17

2.3.8 2D-Barcodescanner VAS 6161/1 ASE 447 043 00 000 .............. 2-18

2.4 Scope of delivery ....................................................................................... 2-21

3 COMMISSIONING ......................................................... 3-1

3.1 Firmware-Update ......................................................................................... 3-1

4 OPERATION ................................................................. 4-1

4.1 Preparation .................................................................................................. 4-1

4.1.1 Charging / Discharging .................................................................... 4-1

4.1.2 Safety test ..................................................................................... 4-10

4.1.3 Self-test ......................................................................................... 4-12

4.1.4 Deviceinfo ..................................................................................... 4-14

4.1.5 Viewing all reports ......................................................................... 4-16

Content

4.1.6 Result report directory ................................................................... 4-18

4.1.7 Entering a list of operator names .................................................. 4-19

4.1.8 Switch off ...................................................................................... 4-19

5 TROUBLESHOOTING .................................................. 5-1

6 MAINTENANCE AND CARE ........................................ 6-1

6.1 Optical check ................................................................ ............................... 6-1

6.2 Cleaning ...................................................................................................... 6-1

7 TECHNICAL DATA ....................................................... 7-1

7.1 Operating data ............................................................................................. 7-1

8 FAULT REPORT FAX ................................................... 8-1

9 INDEX ............................................................................ 9-1

Products are subject to alterations in form, equipment and design. No claims may be made on the basis of the information, graphics and descriptions contained in these instructions. Reprints, copies and translations of this document, in whole or in part, may not be undertaken by third parties without the express written permission of Volkswagen AG and/or the manufacturer. All rights provided under copyright law are expressly reserved by Volkswagen AG and the manufacturer. Subject to alteration. All rights reserved.

VOLKSWAGEN AG Manufacturer: AVL DiTEST GmbH KD-Werkstattausrüstung Alte Poststrasse 156 D-38436 Wolfsburg 8020 Graz AUSTRIA VAS 6910/5 ASE 447 231 00 000 AVL ID-Nr.: AT7784GB Rev. 10

Safety instructions

DANGER

Texts with this symbol contain information relating to your safety and how you can reduce the risk of serious or fatal injuries.

WARNING

Texts with this symbol contain information relating to your safety and how you can reduce the risk of serious injuries.

CAUTION

Texts with this symbol contain information on how you can avoid damage to the vehicle and the device.

NOTICE

Text with this symbol contains additional, useful information.

Information

This text indicates important information or instructions. Failure to comply with these instructions prevents or significantly hampers a successful finalization of the operations described in this documentation.

Safety Instructions

Explanation of symbols

Symbols with the following meanings are used in the safety instructions of the operating manuals, unpacking, start-up and brief instructions or other documentation provided, in screen displays on the tester during operation and on the products themselves:

Additional danger signal:

Danger due to electrical current.

Remarks:

SAFETY INSTRUCTIONS

WARNING

Read all instructions.

WARNING

Requirements needed to operate this device:

- High-voltage technician (HVT)

- High-voltage expert (HVE)

- Electrically qualified person for high-voltage systems in vehicles

- Electrician for special tasks on high-voltage systems in vehicles. If you don’t have any of these qualifications please exit this application immediately!

WARNING

Danger of flashing arcs

Never disconnect wirings while charging or discharging. Opening the cover stops charging / discharging immediately!

WARNING

Use only as described in this manual. Use only the referenced accessories from AVL DiTEST! See chap. 2.2 and 2.4.

WARNING

Use the included mains cord set (power cord)! If the mains cord set has to be changed note the following requirements strictly! On 240 V mains grid the mains cord set must be designed for a continuous current

of 10 A, on 120V mains grid the mains cord set must be designed for a continuous current of 20 A.

The mains cord set must have a C19 plug for the connection to the VAS6910 suitable for the above current ratings.

Connect VAS 6910 only to protective contact sockets! Set up the VAS 6910 in a way that there is always free access to the power separator!! (Power cord from the mains socket).

SICHERHEITSHINWEISE

iii

WARNING

Do not operate equipment with a damaged cord or if the equipment has been dropped or damaged – until it has been examined by a qualified service person.

WARNING

Do not let cord hang over edge of table, bench or counter, or come in contact with hot manifolds or moving fan blades.

WARNING

An extension cord is not allowed. For testing use only specified cables.

WARNING

To reduce the risk of fire, do not operate equipment in the vicinity of open containers of flammable liquids (gasoline).

WARNING

Risk of explosions

The VAS 6910 has internal parts which emit sparks and therefore must not be exposed to flammable fumes. The VAS 6910 should be operated at least 460 mm (18 inches) above the floor surface since fumes from fuels and other materials accumulate at floor level.

WARNING

Connecting non-VW HV-Modules

The VAS 6910 has been developed for vehicles from the Volkswagen group. Connecting the VAS 6910 directly to HV-Modules from other manufacturers can therefore result in damage to the modules and / or the VAS 6910.

WARNUNG

Set up the VAS 6910 so that adequate ventilation is guaranteed, fans and air vents are not obstructed and the air must circulate freely!

SICHERHEITSHINWEISE

WARNUNG

When connecting the cell module, make sure the IR temperature sensor is not covered and ensure direct visibility between the sensor and the module.

CAUTION

The VAS 6910 may only be used within the measurement ranges stipulated in the technical data and descriptions in the operating manual. Do not perform measurements on damaged leads.

CAUTION

Cleaning

Before cleaning the VAS 6910, pull out the USB cable and measuring cables! Clean the VAS 6910 only with a dry cloth. Do not use cleaners or solvents.

READ ALL INSTRUCTIONS - SAVE THESE INSTRUCTIONS!

SAFETY INSTRUCTIONS

IMPORTANT SAFETY INSTRUCTIONS

1. Read all instructions.

2. Care must be taken as burns can occur from touching hot parts.

3. Do not operate equipment with a damaged cord or if the equipment

has been dropped or damaged - until it has been examined by a qualified serviceman.

4. Do not let cord hang over edge of table, bench or counter or come in contact with hot manifolds or moving fan blades.

5. If an extension cord is necessary, a cord with a current rating equal to or more than that of the equipment should be used. Cords rated for less current than the equipment may overheat. Care should be taken to arrange the cord so that it will not be tripped over or pulled.

6. Always unplug equipment from electrical outlet when not in use. Never use the cord to pull the plug from the outlet. Grasp plug and pull to disconnect.

7. Let equipment cool completely before putting away. Loop cord loosely around equipment when storing.

8. To reduce the risk of fire, do not operate equipment in the vicinity of open containers of flammable liquids (gasoline).

9. Adequate ventilation should be provided when working on operating internal combustion engines.

10. Keep hair, loose clothing, fingers, and all parts of body away from moving parts.

11. To reduce the risk of electric shock, do not use on wet surfaces or expose to rain.

12. Use only as described in the manual. Use only manufacturer´s recommended attachments.

13. ALWAYS WEAR SAFETY GLASSES. Everyday eyeglasses only have impact resistant lenses, they are NOT safety glasses.

SAVE THESE INSTRUCTIONS

General Information

1-1

1 General Information

1.1 General Notes

The Module Balancer VAS 6910, here after named VAS6910, is able to charge and discharge single cell modules of high voltage batteries from E-cars and hybrid cars.

To guarantee an overall equal load of all cell modules on a HV-battery, the new cell module has to be charged / discharged to meet this load of the whole battery.

The conditioned „balanced“ cell module replaces the defect cell module. The VAS6910 is designed to use in car shops which have to do HV battery repairs. To use this device you must have a special qualification. See below. Please follow the regulation valid to your country!

Read this operating manual and follow especially the safety hints!

General Information

1-2

1.2 Safety Notes

Please observe the safety instructions for the VAS 6910. You can find them after the contents section.

1.3 Certificate of Calibration

The manufacturer hereby declares (fig 1-1) that the device delivered with this operating manual does not require any calibration within the first 2 years after its delivery. Subsequent calibrations should be carried out every 12 months.

General Information

1-3

Modul-Balancer VAS 6910

Bestellnummer: VS9042

Das Modul-Balancer VAS 6910 wurde unter Einhaltung aller Vorgaben nach der jeweils gültigen Prüfvorschrift erfolgreich getestet und hat in einwandfreiem Zustand unser Haus verlassen.

In den ersten 24 Monaten nach der Auslieferung des Geräts ist keine Kalibrierung erforderlich.

The module balancer VAS 6910 was tested successfully with compliance to all specified values and under the actual test procedure and left our facilities in perfect condition. During the first 24 month after delivery of the device, calibration is not required.

AVL DiTEST ist nach ISO 9001 zertifiziert!

AVL DiTEST is accredited according to ISO 9001!

AVL DiTEST GmbH - Alte Poststrasse 156 - 8020 Graz - AUSTRIA

Fig. 1-1 Certificate of initial calibration

General Information

1-4

WARNUNG

The Housing should only be opened by service personal. See Service information, Chap. 3.1. Regional Service partners).

1.4 Designated Use

It’s only allowed to use the VAS 6910 in that way, described in this manual.

The product described has been developed, manufactured and checked according to the relevant safety standards. If the safety instructions are observed, the start-up is carried out as stipulated, the device is used for the intended purpose and the recommended maintenance and care is also observed, then in normal cases there is no danger regarding damages to property or for the health of persons associated with the VAS 6910.

1.5 Associated Documents

Along with this operating manual, which is to be used by the user in the workshop, there are also the following technical documents for the VAS 6910:

 Unpacking instructions, start-up, brief instructions VAS 6910  Registration certificate  Service information

1.6 Field of application

The VAS6910 is designed for charging / discharging of single cell modules of a HV battery to a certain load level.

Components

2-1

2 Components

2.1 VAS 6910 Adapter and transport box

Adapter and transport box (top view)

Fig. 2-1 Adapter and transport box (top view)

(1) Window

Components

2-2

Adapter and transport box (front view)

Fig. 2-2 Adapter and transport box (front view)

(1) Carrying handle

Adapter- and transportation box (side view left/right)

Fig. 2-3 Adapter and transport box, closed (side view)

(1) Carrying handle (2) Latch (3) Latch

Components

2-3

Adapter and transport box open with Module-Balancer (top-view)

Fig. 2-4 Adapter und transport box open (top view).

(1) Carrying handle (2) Module-Balancer (3) Adapter- and transportation box, (bottom part)

Components

2-4

Adapter and transport box open, Module-Balancer mounted, no cell module (side view)

Fig. 2-5 Adapter and transportation box open, side view

(1) Module-Balancer (2) Adapter- and transportation box, bottom part

Components

2-5

Adapter und transport box open, Module-Balancer attached and cell module inserted, side view.

Fig. 2-6 Adapter and transport box open with cell module inserted, side view

(1) Cell module (2) Module-Balancer (3) Adapter and transport box (bottom part)

Components

2-6

2.2 VAS 6910 Module-Balancer

VAS 6910 Module-Balancer, rear view

Fig. 2-7 VAS 6910 Module-Balancer, rear view

(1) Carrying handle

Components

2-7

WARNING

Set up the VAS 6910 so that adequate ventilation is guaranteed, fans and air vents are not obstructed and the air must circulate freely!

3 4

VAS 6910 Module-Balancer, side view right

Fig. 2-8 Electronic box, side view right

(1) Specification plate (2) USB-connector (rugged) for connection of the USB cable (3) Air inlet grill (6) Power supply inlet. Connection for power cord

Components

2-8

WARNING

current of 10 A, on 120V mains grid the mains cord set must be designed for a continuous current of 20 A.

The mains cord set must have a C19 plug for the connection to the VAS6910 suitable for the above current ratings.

Connect VAS 6910 only to protective contact sockets! Set up the VAS 6910 in a way that there is always free access to the power separator!! (Power cord from the mains socket).

+ 45 hidden pages

Volkswagen VAS 6910 Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Safety instructions

1 General Information

1.1 General Notes

1.2 Safety Notes

1.3 Certificate of Calibration

1.4 Designated Use

1.5 Associated Documents

1.6 Field of application

2 Components

2.1 VAS 6910 Adapter and transport box

2.2 VAS 6910 Module-Balancer