Volkswagen VAS 6910 Operating Manual

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Operating manual V10.00

11/18

Module-Balancer VAS 6910

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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

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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

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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:

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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).

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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!

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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!

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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

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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!

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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.

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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

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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.

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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

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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

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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)

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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

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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)

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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

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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

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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).

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Components

2-9

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!

VAS 6910 Module-Balancer, side view left

Fig. 2-9 VAS 6910 Module-Balancer, side view left

(1) Air inlet grill

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Components

2-10

5 6 7

VAS 6910 Module-Balancer, front view

Fig. 2-10 VAS 6910 Module-Balancer, front view

(1) Connector „Minus“ (black) (2) Connector „CAN“ (3) Connector „U Slave/Sim“ (4) Connector „Plus“ (red)

(5) LED blue  Device on and ready

blue flashing  Device is idle

(6) LED red  Charging / discharging is running

green  No charging / discharging active

(7) IR temperature sensor

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Components

2-11

VAS 6910 Module-Balancer, top view

Fig. 2-11 Module-Balancer, top view

(1) Carrying handle

(2) On / Off button green Power module ON (active mode) red Power module OFF (idle mode)

(3) LEDs blue  Device is on and ready blue blinking  Stand-by / idle mode green  No Charging / discharging is running red  Charging / discharging is active or an error has

happened.

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Components

2-12

2.3 Cable sets

2.3.1 USB-Cable (USB 2.0 Fischer to USB 2.0 B Rugged) BV8139, VAS 611003, ASE 611 003 00 000

This USB cable connects the Module Balancer VAS 6910 to the VW Diagnostic system. Free Fischer connector is needed.

Fig 2-12 USB-cable USB 2.0 Fischer to USB 2.0 B Rugged

2.3.2 USB-cable (USB 2.0 A to USB 2.0 B Rugged) EX7069, VAS 611001 ASE 611 001 00 000

This cable is used if no Fischer connector is available at the VW Diagnostic system.

Fig 2-13 USB-Cable USB 2.0 A to USB 2.0 B Rugged

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Components

2-13

(1)

(2)

(3)

(4)

(5)

(6)

2.3.3 Basic cable set Module adaption 1 (e-up!) VAS 6910/10 ASE 447 240 00 000 BO7852

This cable set consists of 6 cables:

1. VAS 6910/10-1 ASE 447 246 00 000 BV8190 Cable for „Plus“-Pol

2. VAS 6910/10-2 ASE 447 247 00 000 BV8191 Cable for „Minus“-Pol

3. VAS 6910/10-3 ASE 447 248 00 000 BV8140 Analog-Meas. lead for module variant 12E.915.591

4. VAS 6910/10-4 ASE 447 249 00 000 BV8141 Analog-Meas. lead for module variant 12E.915.592

5. VAS 6910/10-5 ASE 447 250 00 000 BV8142 Analog-Meas. lead for module variant 12E.915.591.A

6. VAS 6910/10-6 ASE 447 251 00 000 BV8143 Analog-Meas. lead for module variant 12E.915.592.A

Usage is on e-UP! 2014

Fig 2-14 Basic cable set Module adaption 1 (e-up!)

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Components

2-14

(1)

(2)

2.3.4 Extension cable set Module adaption A (e-Golf) VAS 6910/11 ASE 447 241 00 000 BO7853

Set consists of:

1. VAS 6910/11-1 ASE 447 257 00 000 BV8145 Slave Simulation cable for Master-Modules

2. VAS 6910/11-2 ASE 447 258 00 000 BV8146 Analogue meas. cable for Slave-Modules

For Volkswagen e-Golf cable sets VAS6910/11 (this one) and the VAS6910/12A are necessary!

Start of usage is at e-Golf production year 2014 ff.

Fig 2-15 Kabelsatz e-Golf

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Components

2-15

(1)

(2)

(3)

2.3.5 Basic cable set Module adaption 2 (PHEV) VAS 6910/12A ASE 447 242 01 000 BO7854

The Basic Cable Set Module adaption (PHEV) consists of three cables:

1. VAS 6910/12A-1 ASE 447 252 00 000 BV8188 Cable for “plus” with loose cable clips for use with PHEV modules, AUDI A3 e-tron, e-Golf and Golf GTE.

2. VAS 6910/12A-2 ASE 447 253 00 000 BV8189 Cable for „minus“ with loose cable clips for use with PHEV modules, AUDI A3 e-tron, e-Golf and Golf GTE.

3. VAS 6910/12A-3 ASE 447 254 00 000 BV8265 CAN cable for connecting to the module controller

Start of usage is on E-Golf and PHEV from manufacture year 2014 ff.

Fig: 2-16 Basic cable set Module adaption 3 (PHEV)

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Components

2-16

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 BO7855

The Basic Cable Set Module adaption 3 consists of three cables:

1. Cable for „plus“ Loose cable clip and M6 knurled nut BV8190

2. Cable for „minus“ Loose cable clip and M6 knurled nut BV8191

3. CAN cable for module BV8200

- Porsche G1 II PHEV 24 Ah

- Porsche E2 II PHEV 28 Ah

Start of usage is on Porsche Cayenne and Panamera Hybrid.

Fig 2-17 Adapter cable Porsche G1 II & E2 II PHEV

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Components

2-17

2.3.7 Basic cable set Module adaption 4 (XL1) VAS 6910/14 BO7865 Purchase via r XL1 After Sales Volkswagen AG

The Basic Cable Set XL 1 consists of three cables:

1. Cable for „plus“ Loose cable clip and M6 knurled nut BV8190

2. Cable for „minus“ Loose cable clip and M6 knurled nut BV8191

3. Analogue cable for XL 1 BV8193

Start of usage is on VW XL 1.

Fig 2-18 Basic Cable Set XL 1

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Components

2-18

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

The scanner is used to scan the bar code attached to the cell modules. The canner has an USB-Type A connector and has to be connected to the VW Diagnostic system (VAS 6150A / VAS 6051B / VAS 6160).

Fig. 2-19 2D-Barcodescanner

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Components

2-19

(1)

(2)

(1)

(2)

2.3.9 Basic cable VAS 6910/15

1. VAS 6910/15-1 ASE 447 255 00 000 BV8294 e - Up R Analog connection cable for module variant 12E.915.592.B/…..592.C

2. VAS 6910/15-2 ASE 447 256 00 000 BV8295 e - Up L Analog Analog connection cable for module variant 12E.915.591.E/….591.F

Fig 2-20 Basic Cable

2.3.10 Basic cable VAS 6910/16

1. VAS 6910/16-1 ASE 447 245 00 000 BV8296 CCE Analog connection cable for slave modules

2. VAS 6910/16-2 ASE 447 259 00 000 BV8315 CMC-CCE slave simulation e-Golf 300 GP

Fig 2-21 Basic Cable

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Components

2-20

(1)

(2)

2.3.11 Basic cable VAS 6910/17

1. VAS 6910/17-1 ASE 447 260 00 000 BV8317 For connection to Audi e-tron (C-BEV), module 4KE.915.591.D, 3S4P „normal“

2. VAS 6910/17-2 ASE 447 261 00 000 BV8318 For connection to Audi e-tron (C-BEV), module 4KE.915.591.E, 3S4P „mirrored“

Fig 2-2 Basic cable VAS 6910/17

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Components

2-21

Components

System-

delivery

Accessories

VAS 6910 VAG-No.: ASE 447 230 00 000 AVL-No.:

Module-Balancer VAS 6910 incl. power cord incl. Unpacking und Start Up Manual (printed copy)

●

VAS 6910/1 VAG-No.: ASE 447 231 00 000 AVL-No.: BG7455

Adapter- und Transport box

●

VAS 6910/2 VAG-No.: ASE 447 232 00 000 AVL-No.: BO7841

Module-Balancer incl. power cord

●

VAS 611003 VAG-No.: ASE 611 003 00 000 AVL-No.: BV8139

USB-cable (USB 2.0 Fischer to USB 2.0 B Rugged)

●

VAS 611001 VAG-No.: ASE 611001 00 000 AVL-No.: EX7069

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

●

VAS 6910/5 VAG-No.: ASE 447 235 00 000 AVL-No.: BO7859

Operating manuals and software on CD

●

2.4 Scope of delivery

Table 2-1 scope of delivery

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Components

2-22

Components

Systemdelivery

Accessories

VAS 6910/10 VAG-N0.: ASE 447 240 00 000 AVL-No: BO7852

Basic cable set module adaption 1: e-up (VW120/7)

1. VAS 6910/10-1 ASE 447 246 00 000 BV8190 Cable for „Plus“-Pol

2. VAS 6910/10-2 ASE 447 247 00 000 BV8191 Cable for „Minus“-Pol

3. VAS 6910/10-3 ASE 447 248 00 000 BV8140 Analog-Meas. lead for module variant 12E.915.591

4. VAS 6910/10-4 ASE 447 249 00 000 BV8141 Analog-Meas. lead for module variant 12E.915.592

5. VAS 6910/10-5 ASE 447 250 00 000 BV8142 Analog-Meas. lead for module variant 12E.915.591.A

6. VAS 6910/10-6 ASE 447 251 00 000 BV8143 Analog-Meas. lead for module variant 12E.915.592.A

●

VAS 6910/11 VAG-Nr.: ASE 447 241 00 000 AVL-Nr.: BO7853

Extension cable set module adaption A: E-Golf (VW370/7) Set consists of

1. VAS 6910/11-1 ASE 447 257 00 000 BV8145 Slave Simulation cable for Master-Modules

2. VAS 6910/11-2 ASE 447 258 00 000 BV8146 Analogue meas. cable for Slave-Modules

For VOLKSWAGEN E-Golf both cable VAS 6919/11 and VAS 6910/12A are necessary!

●

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Components

2-23

VAS 6910/12A VAG-Nr.: ASE 447 242 01 000 AVL-Nr.: BO7854

Basic cable set module adaption 2 (PHEV):

1. VAS 6910/12A-1 ASE 447 252 00 000 BV8188 Cable for “plus” with loose cable clips for use with PHEV modules, AUDI A3 e-tron, e-Golf and Golf GTE.

2. VAS 6910/12A-2 ASE 447 253 00 000 BV8189

Cable for „minus“ with loose cable clips for

use with PHEV modules, AUDI A3 e-tron, e-Golf and Golf GTE.

3. VAS 6910/12A-3 ASE 447 254 00 000 BV8265 For: e-Golf, Group module (PHEV) CAN cable for connecting to the module controller

For PHEV module and for AUDI A3-e-tron

●

VAS 6161/1 VAG-Nr.: ASE 447 043 00 000 AVL-Nr.:

2D-bar code reader with USB cable. Distribution Volkswagen AG only!

●

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Components

2-24

Components

System-

delivery

Accessories

VAS 6910/13 VAG-Nr.: ASE 447 243 00 000 AVL-Nr.: BO7855

Basic cable set module adaption 3 Adapter cable Porsche G1 II & E2 II PHEV

1. cable for „plus“ loose cable clip and M6 knurled nut BV8190

2. cable for „minus“ loose cable clip and M6 knurled nut BV8191

3. CAN cable BV8200

●

VAS 6910/14 Purchase via r XL1 After Sales Volkswagen AG AVL-Nr.: BO7865

Basic cable set module adaption 4 Adapter cable XL 1

1. cable for „plus“

loose cable clip and M6 knurled nut BV8190

2. cable for „minus“

loose cable clip and M6 knurled nut BV8191

3. Analogue cable for module XL 1 BV8193

●

Basic Cable VAS 6910/15:

1. VAS 6910/15-1 ASE 447 255 00 000

BBV8294 e - Up R Analog connection cable for module variant 12E.915.592.B/…..592.C

2. VAS 6910/15-2 ASE 447 256 00 000

BV8295 e - Up L Analog Analog connection cable for module variant 12E.915.591.E/….591.F

●

Basic Cable VAS 6910/16

1. VAS 6910/16-1 ASE 447 245 00 000

BV8296 CCE Analog connection cable for slave modules

2. VAS 6910/16-2 ASE 447 259 00 000

BV8315 CMC-CCE slave simulation e-Golf 300 GP

●

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Components

2-25

Basic Cable VAS 6910/17

1. VAS 6910/17-1 ASE 447 260 00 000

BV8317 For connection to Audi e-tron (C-BEV), module 4KE.915.591.D, 3S4P „normal“

2. VAS 6910/17-2 ASE 447 261 00 000 BV8318

For connection to Audi e-tron (C-BEV), module

4KE.915.591.E, 3S4P „mirrored“

●

WARNING

Use only the referenced accessories from AVL DiTEST!

WARNING

of 10 A, on 120 V 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 VAS 6910 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).

Page 38

Commissioning

3-1

3 Commissioning

Use the “Unpacking- Start-up and brief instructions” manual for the VAS6910.

3.1 Firmware-Update

To do an update of the VAS 6910 firmware proceed as follows:

1. Start the update program by click on

Start│All programs│DiTEST│VAS6910│VAS 6910 Firmware Update.

2. Click the OK Button twice. The newest program version and the actual installed version are shown.

If a newer version is available please start the update process by clicking on the then enabled Start button.

3. Follow the instructions on the screen.

Fig. 3-1 Firmware Update

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Operation

4-1

4 Operation

4.1 Preparation

Prepare the VAS 6910 for operation. ( chapter. 3 „Commissioning“).

4.1.1 Charging / Discharging

1. Put the cell module (1) to charged/discharged into the adaption box of the VAS6910.

Fig. 4-1 Cell module inserted

Page 40

Operation

4-2

2. Start the VAS Manager by selecting: Start│Programs│

DiTEST│VAS DSS.

3. Select Diagnose│Module Balancer.

Fig. 4-2 DSS Manager

4. The start screen appears: Select Charge/Discharge.

Fig. 4-3 Start screen

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Operation

4-3

WARNING

Read and follow the safety instructions carefully!

5. A screen with safety instructions is shown next.

6. Please read the instructions and confirm by clicking F8 Next.

Fig. 4-4 Screen with safety instructions

Page 42

Operation

4-4

7. Please enter your name. (Input user name, see chapter 4.1.6 “Input user name“).

8. Continue by clicking F8 Next.

Fig. 4-5 Screen „Enter operator name“

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Operation

4-5

3 4 1

9. Scan the bar code label attached to the cell module. Field „Scan-code“ (1) shows the scanned cell module information data. Module type (2) and the serial (3) are filled in automatically.

If no bar code reader is available: Choose a cell module type from the drop down list (2) and enter a serial number (3).

Input the avg. cell voltage (4). This value is given by the VW Off-board diagnostic system.

10. Confirm by clicking F8 Next.

Fig. 4-6 Screen „Select cell module“

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Operation

4-6

WARNING

Execute pt. 3 and 4 in the shown order!

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.

11. The next screen guides you through the connection process.

It is important to do all connecting work in the shown order.

12. Continue by clicking F8 Next. Click on the button to get a picture schowing where to connect the

cable.

Fig. 4-7 Screen „Connecting the Cell module“

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Operation

4-7

13. The cell module gets charged/discharged now. Section 1 shows all relevant data.

By clicking F6 Stop you can stop the charging / discharging process.

14. After the charging / discharging is finished please click F8 Next.

Fig. 4-8 Screen „Charging/ discharging“

Page 46

Operation

4-8

15. A screen appears which shows you how to disconnect the charged / discharged cell module. Please follow the exact order shown.

16. Continue with F8 Next.

Fig. 4-9 Screen „Disconnect cell module“

Page 47

Operation

4-9

17. On this screen the result protocol is shown.

F4 Print Starts a print out of the protocol. F5 Edit The protocol can be edited.

18. By pressing F8 Next the charge / discharge process is finished.

Fig. 4-10 Screen „Report“

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Operation

4-10

4.1.2 Safety test

1. Start the VAS Manager by selecting: Start│Programs│

DiTEST│VAS DSS.

2. Select Diagnose│Module Balancer.

Fig. 4-11 DSS Manager

3. The start screen appears: Select Safetytest.

Fig. 4-12 Start screen

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Operation

4-11

4. Follow the on-screen instructions. Continue with F8 Next.

Fig. 4-13 Safetytest

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Operation

4-12

4.1.3 Self-test

1. Start the VAS Manager by selecting: Start│Programs│

DiTEST│VAS DSS.

2. Select Diagnose│Module Balancer.

Fig. 4-14 DSS Manager

3. The start screen appears: Select Selftest.

Fig. 4-15 Start screen

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Operation

4-13

4. The self-test is performed and the result displayed.

Return to the Start screen with F8 Next.

Fig. 4-16 Selftest

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Operation

4-14

4.1.4 Deviceinfo

1. Start the VAS Manager by selecting: Start│Programs│

DiTEST│VAS DSS.

2. Select Diagnose│Module Balancer.

Fig. 4-17 DSS Manager

3. The start screen appears: Select Deviceinfo.

Fig. 4-18 Start screen

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Operation

4-15

4. A screen appears with the device data.

With F8 Next to the home screen.

Fig. 4-19 Deviceinfo

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Operation

4-16

4.1.5 Viewing all reports

With this function you can manage the result protocols. Click on Result Management.

Fig. 4-10 Result management

Source

Select Local / Network / Saved Results.

Period

Select Day, Week, Month, Year or All. You can flip forwards and backwards using the arrows.

Report type

Select Proof / Diagnosis Logs etc.

Search text

Choose between “None”, “Manufacturer” or “Licence number”. In the Search text field, you can narrow the selection down further.

Return to “Results Management” with Quit.

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Operation

4-17

 Individual logs can be selected by checking a box.

F2 Choose Selects all logs. F3 Discard Discards the log selection. F4 Print Prints the selected logs. F5 Delete Deletes the selected logs. F6 Export Exports the selected logs.

F5 Directory Opens a window to choose the save location.

Choose a location and then click OK. F8 Next Starts the export.

F7 Archive Archives the selected logs.

The archived logs will be deleted from the internal database.

F5 Directory Opens a window to choose the save location.

Choose a location and then click OK. F8 Next Starts the archiving.

<< Cancel Quits the results display.

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Operation

4-18

4.1.6 Result report directory

Result protocols are stored for future use at the default location: “C:\Users\Public\Documents\xxxx“.

This location can be changed: Click on ExtrasSettingsAVL DiGate480.

Fig. 4-11 Changing the Report protocol directory

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Operation

4-19

4.1.7 Entering a list of operator names

Using this function you can manage a list of operator names. The list appears in operation mode charge/discharge, see Fig.4-5.

Click on ExtrasSettingsPersons (see chapter 4-11). Clicking New opens an input window into which you can enter the

name of a new tester. Return to “Tester” with OK.

Clicking Delete deletes the blue-highlighted operator name. Clicking Edit opens an input window in which you can edit the

blue-highlighted tester name. Return to “Tester” with OK.

Clicking Current Operator selects the blue-highlighted operator name (or clicking the desired operator name).

Clicking Responsible Operator selects the blue-highlighted tester name (or clicking the desired operator name).

4.1.8 Switch off

The VAS 6910 has no on/off switch. With the button, see fig. 2-8, only the power modules are switched off. The VAS 6910

enters Idle, Sleep mode. To disconnect the VAS 6910 from the power grid press the red button (Power module

off) and disconnect the power cable from the wall outlet.

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Troubleshooting

5-1

DANGER

Danger to life by electrical shock

Maintenance is only allowed by service staff! Do not open the VAS 6910, because exposed parts can have dangerous voltages!

5 Troubleshooting

Maintenance

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Maintenance and care

6-1

CAUTION

Damaged Parts (power cord, adapter and US cables) have to be exchanged immediately!

CAUTION

Before cleaning the VAS 6910, switch off the Power module and remove the mains plug! Remove all adapter cables! Be sure that no liquid is flowing into the housing of the VAS 6910!

6 Maintenance and care

6.1 Optical check

Carry out a regular optical check of the VAS 6910, USB cable and measuring cables with the test adapters. Check for damage and dirt.

6.2 Cleaning

If the housing is dirty and you want to clean it, please use a dry cloth.

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Technical data

7-1

AC-Power grid Nominal voltage range

Power supply Frequency Power consumption

100 … 240 V~

50 ... 60 Hz 2,15 kW

Charging power

max. 2 kW (max. Current: 50 A)

Discharging power

max. 400 W (max. Current: 10 A)

Cell monitoring (charge/Discharge)

Depends on type of cell module:

- Analogue meas. of cell voltages and temperatures

- Monitoring via CAN bus to the cell module controller Monitored values are Voltages, currents and temperatures.

External interface

USB

USB 2.0-Rugged

Ambient conditions Operating

Transport and storage

Ambient temperature Relative humidity

0 to +40 °C at max. +25 °C 10 to 80 % non condensing

-20 to +55 °C at max. +20 °C 10 to 80 %, non condensing

Electrical protection and storage

Safety regulations

Measurement device: DIN EN 61010-1 (VDE 0411 part 1) IEC 1010-1 Garage equipment: UL 201 GARAGE-EQUIPMENT

- Protection class I

- Degree of protection IP30

7 Technical data

7.1 Operating data

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Fault reportfax

8-1

8 Fault report fax Fax No.:

Please fill in the relevant sections completely (if possible in English, French or German) and then fax it to the relevant regional service centre, see Service information, chapt. 3-1 Regional service centres.

1. Registration details

Serial number Is your warranty still valid (24 months)? Ja 

If yes, please enclose the guarantee proof (registration and delivery receipt as a copy)

2. Dealership details

VW-affiliate workshop  Independent workshop  Sales centre / importer no. Name of company Tax ID no. Contact person Telephone / Fax Postal address: Delivery address (if different to postal address): Street No. Street No. Postal code City Postal code City

Country Country

Phone-No. Phone-No. Fax. Fax.

1. As to be entered / already entered on the tester (see Operating Manual)

2. For EU countries only

Please provide additional information as requested on the following page.

Dealership number1

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Fault report

8-2

Fault report fax, second page

3. Description of problem

Basic problems

Was the start-up dialogue box displayed on-screen? Yes ❏ Can you load/launch the calibration program? Yes ❏ Does the fault relate to the USB port? Yes ❏

Fault image or error message:

Is it possible that an adaption cable causes the error? Yes ❏ (see sections 2 and 4 of the operating manual)

❏ VAS 6910/1 ❏ VAS 6910/11 ❏ VAS 6910/2 ❏ VAS 6910/12A ❏ VAS 611003 ❏ VAS 6910/13 ❏ VAS 611001 ❏ VAS 6910/14 ❏ VAS 6910/5 ❏ VAS 6910/15 ❏ VAS 6161/1 ❏ VAS 6910/16 ❏ VAS 6161/10 ❏ VAS 6910/17

Is the fault reproducible? Yes ❏ Does the fault occur sporadically? Yes ❏

What software firmware versions are you running?

(Choose from VAS-Manager Service/Maintenance>System-info>without devices) Module Balancer:

Please provide additional information as requested on the following page.

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Fault report

8-3

Fault report fax, third page

In which operating mode did the fault occur?

During charging? Yes ❏ During discharging? Yes ❏ While in safety test? Yes ❏ When self-test was running? Yes ❏

Last message text in the calibration program:

(see „Program hints"‘ box)

Space for further messages:

Does the fault report fax have any attachments?

Screenshot with error messages? Yes ❏

We have read the service conditions for the replacement of components and we hereby accept these conditions.

City Date Signature Stamp

Page 64

Index

9-1

9 Index

Associated Documents 1-5

Cable sets 2-11 Certificate of Calibration 1-2 Charging / Discharging 4-1 Cleaning 6-1 Commissioning 3-1 Components 2-1

Designated Use 1-4

Entering a list of operator names 4-15 Explanation of symbols i

Fault report fax 8-1 Field of application 1-4

Maintenance 5-1 Maintenance and care 6-1

Operating data 7-1 Operation 4-1 Optical check 6-1

Preparation 4-1

Result report directory 4-14

Safety Instructions i Safety Notes 1-2 Safety test 4-10 Scope of delivery 2-16 Self-test 4-11 Switch off 4-16

General Information 1-1 General Notes 1-1

Technical data 7-1 Troubleshooting 5-1

VAS 6910 Module-Balancer 2-6 Viewing all reports 4-12

Page 65

9-2

We have checked the contents of the documentation to ensure they correspond to the status described. Nevertheless deviations cannot be entirely excluded and we cannot therefore guarantee complete agreement. The information in this documentation is however regularly reviewed and any corrections necessary will be incorporated in the next edition. We will be grateful to receive suggestions for improvement.

Products are subject to alterations in shape, equipment and design. For this reason, no claims may be made on the basis of the information, graphics and descriptions contained in this operating manual. Reprints, copies and translations of this document, in whole or in part, may not be undertaken without the express written consent of Volkswagen AG and/or the manufacturer with the exception that the user documentation may be supplied with each tester. Making available to third parties is not permitted. All rights provided under copyright law are expressly reserved by Volkswagen AG and the manufacturer. Subject to alteration. All rights reserved.

VOLKSWAGEN AG KD-WERKSTATTAUSRÜSTUNG D-38436 Wolfsburg

Manufacturer: AVL DiTEST GmbH

Alte Poststrasse 156 8020 Graz AUSTRIA