akkuteam VAS 5581 User manual

HV Measurement
Adapter
VAS 5581 Operating Instructions
EN
Theodor-Heuss-Straße 4
D-37412 Herzberg am Harz
Telefon [phone]
Fax [phone]
[email protected]
www.akkuteam.de

Operating Instructions
HV Measurement Adapter VAS 5581
www.akkuteam.de V 1.02 3
Table of Contents
1.0 Safety instructions .......................................................................................... 3 – 10
1.1 Instructions for the manual ........................................................................ 11
1.2 Pictograph legend ....................................................................................... 12
1.3 Labeling on the HV Measurement Adapter ........................................... 13
2.1 Safety instructions ................................................................................................. 14
2.2 Maintenance and repair .............................................................................. 15
3.0 Keyboard assignments ................................................................................ 16 – 17
4.1 Function .................................................................................................................. 18
4.2 Equipment concept ........................................................................................ 18
4.3 Safety .............................................................................................................. 18
4.4 Intended uses ................................................................................................. 19
4.5 Power connection ........................................................................................... 19
4.6 Startup ................................................................................................... 19 – 21
4.6.1 Installing the lithium-ion battery ...................................... 22 – 23
4.6.2 Battery status indicator and charging the battery .............. 24
4.7 Function description ............................................................................. 25 – 26
4.8 Firmware update ............................................................................................ 27
4.9 Supplied content ............................................................................................ 27
5.0 Product warranty................................................................................................... 28
6.0 Cleaning and decontamination ......................................................................... 28
7.0 Technical specications ................................................................................ 29 – 30
1.0 Safety
Instructions
Safety
Instruction
Explanations
DANGER! Refers to an imminent danger.
Not observing these risks can result in death or serious
injuries.
WARNING! Refers to a potentially
dangerous situation. Not observing these risks can
result in death or serious injuries.
CAUTION! Refers to a potentially damaging situation.
Not observing these risks can result in minor injuries
and property damage.
NOTE! Refers to a risk of poor quality work results and
the potential for damaging the equipment.
IMPORTANT! Refers to application tips and other particularly use-
ful information. It is not intended as a signal phrase to designate a
damaging or dangerous situation.
Particular attention is required when you see a symbol shown in the
"Safety Instruction" section.

Operating Instructions
HV Measurement Adapter VAS 5581
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General The unit was manufactured in accordance with the state of the art
and the recognized safety-technical regulations. However, risks
continue to exist when the unit is operated inappropriately or
misused, specically for:
– death or bodily injury of the operator or others,
– the unit or other property of the operating entity,
– the ecient operation of the unit.
All personnel who are involved with commissioning, operating,
maintaining and servicing the unit must
– have the appropriate qualications,
– have fully read and accurately follow these operating instructions.
The operating manual must be stored at the operating location
of the unit at all times. In addition to the operating manual, all
generally applicable and local accident prevention and environ-
mental protection regulations must be observed.
All safety and hazard labels on the unit
– must be legible
– must not be damaged
– must not be removed
– must not be concealed, taped over or painted over.
You can nd the locations of the safety and hazard labels on the
unit in the "General Information" section of the unit operating
manual.
Malfunctions that compromise safety must be corrected before the
unit is turned on. This involves your personal safety!
The unit must only be used for the intended purposes.
Any other uses are in violation of the intended uses.
The manufacturer is not liable for any losses and decient or
defective work output resulting from such uses.
The intended uses also include
– having fully read and complying with the operating manual and
all safety and hazard instructions
– observing inspection and maintenance schedules
– observing all instructions by the battery and
vehicle manufacturer
Operating or storing the unit outside of the indicated areas is a
violation of the intended uses. The manufacturer is not liable for
losses resulting from this.
Precise information about the approved environmental conditions
can be found in the accompanying technical specication sheet.
Due to their power consumption, equipment with high power
ratings can negatively inuence the electrical power supply grid.
This can impact certain equipment types in the form of:
– connection restrictions
– requirements with respect to the maximum rated
grid impedance*)
– requirements with respect to minimum
short-circuit rating*)
*) respectively at the interface to the public utility grid
see technical specications
Intended
uses
Environmental
conditions
Power
connection

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HV Measurement Adapter VAS 5581
www.akkuteam.de V 1.06 7
In this case, the operating entity or user of the unit
must determine whether the unit may be connected, possibly by
contacting the electrical power utility.
You are exposed to a host of hazards when working with the HV
Measurement Adapter, such as
– electrical hazards from the grid and charging current
– hazardous electro-magnetic elds, which are a deadly hazard
for persons with pacemakers
An electrical shock can be deadly. Any electrical shock is categori-
cally a deadly hazard. In order to avoid electrical shocks during
operation:
– do not touch live components inside or outside of the unit.
– never touch the battery plugs
– do not short-circuit the inspection or charging cable
All cables and lines must be rigid, undamaged, insulated and
appropriately sized. Loose connections, burned, damaged, or
undersized cables and lines must be immediately serviced by a
certied facility.
Keep people, especially children, away from the unit and the work-
space while the unit is in operation. If people are nevertheless in
the proximity
– notify the persons about the hazards from the grid and charging
current,
– provide appropriate safety gear.
When leaving the workspace, ensure that bodily injury and prop-
erty damage cannot be sustained while you are away.
Hazards
due to grid
and charging
current
Personal and
personnel safety
Safety steps
during normal
operations
EMC device
classications
Only operate units with a protective ground wire on a grid with
protective ground wire and a power outlet with protective ground
wire. If the unit is operated on a grid without protective ground
or on a power outlet without protective ground this is considered
to be grossly negligent. The manufacturer is not liable for losses
resulting from this.
– only operate the unit in accordance with the protection type
indicated on the rating plate,
– never operate the unit when it has been damaged,
– regularly have a certied electrician inspect the protective
ground wire of the power and unit cable for function,
– before turning the equipment on, have a certied service facility
repair not fully operational safety equipment and components
that are not in proper working condition,
– never bridge or otherwise disable safety features,
– a freely accessible power outlet is needed while the unit
is in use.
Equipment of emission class A:
– is only intended for use in industrial zones
– can cause cable-borne and radiating malfunctions in other
zones.
Equipment of emission class B:
– meet the emission requirements for residential and industrial
zones. This also applies to residential zones where the energy
supply originates from the public low-voltage grid.
EMC device classication as per the rating plate or the
technical specications.

Operating Instructions
HV Measurement Adapter VAS 5581
www.akkuteam.de V 1.08 9
In special circumstances, the intended application may be impacted
in spite of adhering to the standardized emission threshold values
(e.g. when sensitive equipment is located near the equipment or when
the unit is located in the proximity of radio or television receivers). In
such cases, the operating entity is required to take appropriate steps
to correct the malfunction.
Under normal conditions, the unit requires only a minimum
of care and maintenance. However, it is essential that several issues
are observed to maintain the operational status over a period of
several years.
– check the power plug and power cable for damage before each
use
– clean the unit with a soft, dry cloth when the housing
surface is soiled
Repair and service work must only be performed by an authorized
service facility. Use only original spare and wear parts (this also
applies to standard components). Components sourced from third
parties may not be designed and manufactured in accordance with
safety requirements.
Do not install other devices in the equipment or make modications
to the equipment without the manufacturer's approval.
The product warranty period for the unit is 2 years from the date of
the invoice. However, the manufacturer will not honor the product
warranty if the damage was caused by one or several of the following:
– use of the equipment in violation of its intended uses
– improper installation and operation
– operating the equipment with defective safety equipment
– non-compliance with the instructions in the operating manual
– unauthorized modications of the equipment
– catastrophic events due to foreign objects and force majeure
The manufacturer recommends having a safety-technical inspection
performed on the equipment at least every 12 months.
We recommend a safety-technical inspection by a certied
electrician
– after modications
– after installing other components or modications
– after repairs, service and maintenance
– at least every 12 months.
Conduct the safety-technical inspection in compliance with
the applicable national and international standards and
directives.
You can obtain more detailed information about the safety-
technical inspection from your electrical testing center, which
will provide you with the required documentation upon request.
EMC
features
Maintenance
and repair
Product
warranty
and liability
Safety-technical
inspection

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HV Measurement Adapter VAS 5581
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Devices with the CE marking meet the basic requirements
of the low-voltage and electro-magnetic compatibility
directive.
Devices marked with this TÜV test seal meet the
requirements of the applicable standards for Canada
and the USA.
Devices marked with this TÜV test seal meet the
requirements of the applicable standards for Japan.
Devices marked with this TÜV seal and the markings
indicated on the rating plate meet the requirements of
the applicable standards for Australia.
Do not discard this device in the household waste! As per the
European Directive 2002/96/EC for waste electrical and electronic
devices and its implementation into national law, discarded electrical
devices must be separated and recycled in an environmentally
compatible manner. Ensure that your used equipment is returned
to your dealer or obtain information about a local, authorized
collection and disposal system. Ignoring this EU directive can have
a potentially negative impact on the environment and your health.
The copyright to this operating manual remains with the manufac-
turer. The text and gures correspond to the technical status at the
time of printing. Modications made without notice. The content of
the operating manual establishes no claims of any kind by the buyer.
We appreciate suggestions for improvement and for any errors in the
operating manual.
1.1 Instructions for the manual
State of the art
This HV Measurement Adapter corresponds to the current state of the
art. Proper and safety-conscious operation is required to operate the
device safely.
Read the operating manual
Carefully read the operating manual before using the HV
Measurement Adapter. The operating manual must be observed at all
times.
Action
All actions required to correctly operate the unit are described in the
operating manual and in the referenced documents.
Any other practices not explicitly approved by the manufacturer may
not be employed.
The intended protection may be impaired if the unit is not used
as per the operating manual.
General instructions
Inspections, assembly and repair work may only be performed by
personnel trained by the manufacturer. When malfunctions occur, only
those malfunctions may be corrected in-house that have been marked
for the corresponding maintenance processes in the manufacturer's
training documentation.
Safety labeling
Disposal
Copyright

Operating Instructions
HV Measurement Adapter VAS 5581
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1.2 Pictograph legend
Comply with all instructions and safety regulations
This operating manual contains several sections with internationally referenced
warning labels, hazard warnings and general instruction markings.
The individual icons are explained as follows.
Observe operating
manual
Observe general
instructions
No persons with
pacemaker
High voltage! Caution:
deadly hazard!
Attention: dangerous
electrical voltage
Observe the
following!
1.3 Labeling on the HV Measurement Adapters
CE marking
Not for household waste
disposal
Type plate
Risk of electrical shock
Read the operating
manual
before use
Observe quality inspection
notice, serial number
A
Nur bei spannungsfrei geschaltetem Fahrzeug einsetzen.
Use only when vehicle is switched to „No Voltage“.
Monter uniquement sur un véhicule hors tension.
Risk of explosion, this equipment has internal arcing or spar-
king parts which should not be exposed to ammable vapor.
This equipment shoud be located at least 460 mm (18 inches)
above the oor.
WARNING
for service please contact: [email protected]
CAR-connect GmbH
akkuteam Energietechnik GmbH
Am Walde 3
Theodor-Heuss-Straße 4
D-38539 Müden
D-37412 Herzberg am Harz
Aufkleber HVA klein_Druck.indd 2 26.10.2012 14:43:55
Test seal
Workshop equipment
Attention
VAS 5581 quality
tested
SN: 03006-001-XXXXX

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HV Measurement Adapter VAS 5581
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2.1 Safety Instructions
The VAS 5581 Measurement Adapter is exclusively intended for diag-
nostics on high-voltage batteries. The tool may only be used for those
purposes that do not represent a risk for people and machinery. The
VAS 5581 Measurement Adapter may only be used as described in the
operating manual! Any modications on the VAS 5581 HV Measure-
ment Adapter or other uses are made at the operating entity’s risk.
Ensure that the VAS 5581 HV Measurement Adapter is in proper
working order and that all functions are available for safe operation.
Observe the accident prevention regulations applicable in the
respective countries.
Wear personal protective gear!
Never throw or drop the VAS 5581 Measurement Adapter.
Never allow the VAS 5581 Measurement Adapter to
be employed for unintended uses or by untrained personnel!
Ensure that the VAS 5581 HV Measurement Adapter is
employed in a working environment that has no heat sources (max.
40°C / 77°F), and is free of corrosive uids, oil and grease.
The VAS 5581 Measurement Adapter must never be used in explosive
environments.
Ensure that the VAS 5581 Measurement Adapter is placed on a non-
slip surface and that the equipment cannot be damaged. Only use tools
and accessories that are not worn or exhibit other forms of damage.
Damaged tools or accessories can result in serious injuries!
2.2 Maintenance and repair
The manufacturer is not liable for losses that are the result of faulty
repairs or the use of foreign spare parts.
The product warranty is null and void as a result of inappropriate uses
of the measurement adapter that result in damage to the equipment.
When in doubt, always contact a certied service provider
or akkuteam directly. You can nd the corresponding contact
address in this manual.
Any components that have been visibly damaged must be
replaced. Damaged components can result in serious injuries!
Inspect contacts and connections for damage.
Maintenance and repair work may only be performed by
authorized and trained personnel after having been instructed by
akkuteam.
Contact us at our service address for further information about service
work and training:
akkuteam Energietechnik GmbH
Theodor-Heuss-Straße 4
D-37412 Herzberg am Harz
[e-mail]

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3.0 Keyboard
assignments
On/O switch Battery indicator
"Battery empty",
less than 30 %.
"Battery half full",
less than 60 %
"Battery full", 100 %
F1
adds terminal 15.
When the LED is lit, the
associated terminal carries
voltage (12 Volts).
F2
adds terminal 30. When the
LED is lit, the associated termi-
nal carries voltage (12 Volts).
F3
CAN-R select key.
Selects the impedance when
pressed repeatedly Selected
impedance value
F4
activates and deactivates
“close connection” function
OBD plug
Power supply plug
BMS connection cable
USB 2.0 port
Power supply plug
BMS connection cable
USB 2.0 port

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HV Measurement Adapter VAS 5581
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4.1 Function
The VAS 5581 high-voltage measurement adapter is a tool to
diagnose a high-voltage battery that has not been integrated into the
vehicle on-board power grid. The work instructions
of the trouble-shooting procedures published by the respective vehicle
brands of the Volkswagen Group must be observed for this purpose.
4.2 Equipment concept
The measurement adapter can be operated with the power
supply but also independently with the installed battery
(accessory, not included in the supplied contents). To do so,
verify the supplied content to determine whether the device-specic
battery is included. The use of an installed rechargeable battery
increases operational reliability.
The device can be updated and can be adapted for future
applications by means of rmware updates..
4.3 Safety
WARNING! Inappropriate operation can result in seri-
ous bodily injury and property damage. Only perform the
described functions after having read and understood the
following documents:
– operating manual
– all operating manuals for the system components, speci-
cally the safety instructions
4.4 Intended uses
The measurement adapter is only intended for diagnostics as per the
descriptions in the trouble-shooting procedure. Any other uses are in
violation of the intended uses. The manufacturer is not liable for losses
resulting from this. The intended uses also include
– observing all instructions in the operating manual
– regularly inspecting the power cable
4.5 Power connection
The rating plate with the power supply rating is located on the housing.
The device is only designed for this voltage supply. The unit must there-
fore only be operated with the included power supply and power cable.
4.6 Startup
Remove the unit from the carrying case and check the unit for any
damage. The unit works with the installed battery (accessory, not
included in the supplied contents) but also without the battery - but in
this case only when the power supply is connected to a power outlet.
Only use a device-specic original battery!
The original battery VAS 5581/10 is available as an accessory
(Part No. A 000606, ASE-No. 109 051 00 000).
The battery is installed by loosening the 4 screws on the bottom
of the VAS 5581 HV Measurement Adapter and opening the battery
compartment by lifting the device bottom. Insert the battery and
connect the battery plug with the connector terminal that protrudes
from the intermediate unit bottom.

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HV Measurement Adapter VAS 5581
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Close the unit back up with all previously removed screws and check
the proper seat of the unit bottom.
Insert the charger plug of the power supply into the charging plug on
the measurement adapter and plug the power supply into a matching
power outlet. Country-specic power cables can be used as an alterna-
tive on the power supply, provided these are equipped with a Type C6
power plug.
When the power supply is connected to the measurement adapter, the charging
manager of the internal battery is in charge operation mode.
This is indicated by a ashing of the green status LED with the battery symbol
"full battery" and happens regardless of whether or not a battery is installed.
Start the measurement adapter with the green On button The green LED next to the
On switch conrms when the unit is operational. The battery
status indicator indicates the charging status of the installed battery.
When no battery is installed in the measurement adapter, all 3 battery LEDs light
up for 15 seconds and then go dark after the measurement adapter was started.
NOTE! When no battery is installed in the battery compartment, the
measurement adapter can only be operated with a connected power
supply. The operational reliability is increased by installing a device-
specic battery.
NOTE! Only use device-specic batteries (VAS 5581/10)!
(Part No. A 000606, ASE-No. 109 051 00 000).

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HV Measurement Adapter VAS 5581
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4.6.1 Installing the
lithium-ion battery
NOTE!
Make sure that all devices and consumers are
switched o or disconnected from the power supply before
installation.
1. Unscrew and remove the rear cover of the VAS 5581.
2. Place the lithium-ion battery in
the lower area intended for it. The
cable connection should be on
the right side. No further xing in
place is necessary.
Before connecting the battery,
ensure that the device is discon-
nected from the power supply
and switched o.
3. Attach the plug to the circuit
board of the device so that the
white socket guide rail on the
circuit board is able to engage
the recess in the red battery plug
as intended (refer to Figure
2 + 3).
Attaching the plug in a manner
contrary to the instructions
specied above may cause
defects, or result in a short-circuit,
as soon as the VAS 5581 is
switched on.
4. When you are sure that you
have connected the lithium-ion
battery in accordance with the
instructions, screw the rear cover
of the VAS 5581 back on. Your
HV diagnosis box is now ready
for use.
1
2 3

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HV Measurement Adapter VAS 5581
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4.6.2 Battery status indicator and charging the battery
After switching on the VAS 5581 without a connected power supply, the
charge status of the battery is indicated with 3 LEDs next to the battery
symbols. Without an installed battery, the VAS 5581 can only be started
with a power supply connected and plugged into a power outlet.
When no battery is installed in the measurement adapter, all 3 battery
LEDs light up for 15 seconds and then go dark after the measurement
adapter was started.
The charging of the built-in battery will start automatically when the
power supply is connected. The green ashing LED with the battery
symbol "Full Battery" indicates the started charging process. Whenever
the power supply is connected the charging mode will be started when
a battery is installed even when the device is switched o. The regular
charging time of a fully discharged battery is about 12 hours. Partial
charges to maintain the currently required operability are possible at
any time.
The 3 LEDs indicate the charging status when operating the measurement
adapter without a power supply and with the battery installed.
When the red, the yellow and the green LED with the "Full Battery"
symbol is lit, the battery is at a charging status of 100 %. When only
the red and the yellow LED with the "Half-Full Battery" symbol is lit, the
battery is at a charging status of less than 60 %. When only the red
LED with the "Empty Battery" symbol is lit, the battery is at a charging
status of less than 30%.
The cells of the built-in battery need a balancing regularly. This
equalization charge starts automatically when the power supply is
connected. Other features of the device will not be aected. The
balancing will not be signaled separately. It is indicated by the ashing
LED "Full Battery", too. For an ecient balancing the power supply
should stay connected to a VAS 5581 with built-in battery for at least
12 hours. At least every 10 complete discharges of the battery this
special charge should take place during the usage of the VAS 5581.
To visualize the nished balancing while the power supply is connected
the ashing LED will change into a permanent shine after 12 hours.
4.7 Function description
NOTE! As a result of rmware updates, your device may
have functions available that are not described in this
operating manual, or vice-versa. Moreover, individual
graphics may show operator controls that dier slightly from
those on your device. The function of the operator controls is
nevertheless the same.
NOTE! The close contactor function has the eect that KL30C
is supplied with 12V from the BMS and that the pilot line is
closed. You can nd other framework conditions in the repair
guidelines.
WARNING! Inappropriate operation can result in serious
bodily injury and property damage. Only perform the
described functions after having read and understood the
following documents:
– this operating manual
– all operating manuals for the system components,
specically the safety instructions
Insert the diagnostics connector or the radio head (VCI, e.g. VAS 5054)
into the diagnostics port on the VAS 5581. Connect the vehicle-specic
adapter cable into the 10-pin port of the measurement adapter and
connect the other end with the BMS on the HV battery.
The adapter cable specied for use is described in the repair guidelines
or in the guided fault nding. Employing an incorrect adapter cable
may damage the vehicle. The VAS 5581/1 adapter cable is included in
the contents supplied together with the VAS 5581.

Operating Instructions
HV Measurement Adapter VAS 5581
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After being prompted by the guided trouble-shooting procedure, add
terminal 15 and terminal 30 with the F1 and F2 keys. The switching
status of the terminals is indicated by the green LEDs next to the keys.
When the LED is lit, the associated terminal carries voltage (12 Volts).
The electricity is connected to the BMS via the diagnostics port and via
the adapter cable.
Select the CAN termination impedance indicated by the guided trouble-
shooting procedure by repeatedly pressing the CAN-R select (F3) key.
The respectively selected impedance value is indicated by the yellow
LED on the selection row. The measurement adapter is now ready for
communication. Now follow the instructions from the guided trouble-
shooting procedure.
When prompted by the guided trouble-shooting procedure to perform
the “Close Connection” function, press and hold the F4 key on the
measurement adapter for 5 seconds until the blinking “ready” status
LED lights up steadily. Now press the F4 key once again within an
additional 5 seconds, therefore triggering the “Close Connection”
function. This activates the “Close Connection” function. This supplies
terminal 30C with on-board power and the pilot line is closed.
The “Closed” LED now also lights up as a conrmation and the power
supply to terminal 30C drops o.
Pressing the F4 key once again resets the function and the connection is
reopened. This causes the function LEDs to go dark.
The device is shut down by pressing the green On button once.
4.8 Firmware update
NOTE! When a rmware update is made available for
download, the download contains separate operating
instructions for installing the update.
The rmware status of the measurement adapter can be updated.
In order to upload an update revision of the rmware/software,
connect the VAS 5581 to a Windows PC via its USB port. Each new
rmware revision comes with its own detailed instructions.
The rmware revision is published by the sales organization or can be
obtained as a download from akkuteam.
www.akkuteam.de
4.9 Supplied content
1 VAS 5581 Measurement Adapter
1 VAS 5581-1 Adapter cable
1 Power supply - 18 Volt 4.75 A (90-240 VAC 50/60 Hz)
1 Power cable - EU
1 Operating manual
1 Carrying case

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HV Measurement Adapter VAS 5581
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5.0 Product Warranty
The HV Measurement Adapter from akkuteam comes with a product
warranty of 24 months against materials or manufacturing defects.
The product warranty begins on the shipping date as conrmed on the
invoice or the shipping ticket.
The product warranty is valid for the user/buyer, provided the measure-
ment adapter was purchased from an authorized dealer and that it was
used as intended.
The product warranty is null and void if the measurement adapter was
used for other purposes that are in violation of the intended uses.
The warranty expires when the measurement adapter was not used in
accordance with the operating manual.
In case of a defect, akkuteam will at its own discretion repair or replace
only the defective components.
Service Address:
akkuteam Energietechnik GmbH
Theodor-Heuss-Straße 4
D-37412 Herzberg am Harz
[e-mail]
6.0 Cleaning and decontamination
The measurement adapter should only be cleaned with a soft and dry
cloth.
7.0 Technical specications
Electrical specications
Input
Input voltage 18 - 20 V DC
Input current 4.0 - 8.0 A max.
EMC Emission class B
Test seal CE
Electrical specications Output
Nominal output voltage 12 V DC
Output current 3.0 A max.
Battery specications
Lithium-Ion battery 14.80 V 6750 mAh
with protective circuit 99.9 Wh
Use only batteries from the VAS 5581 Series!
(Part No. A 000606, ASE-No. 109 051 00 000).
Technical specications
Cooling Convection
Dimensions l x w x h 234 x 123 x 60 mm
Weight (without cable and battery) 0.562 kg
Weight (with battery) 1.120 kg

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HV Measurement Adapter VAS 5581
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Environmental conditions
Operating temperature 0 °C - +40 °C
Storage temperature -40 °C - +65 °C
Climate class B
Protection class IP20
Standards
IEC 60950-1, UL 60950-1, C22.2 No. 60950-1,
EN 61000-6-3:2007+A1:2011, EN61000-6-2:2005, ICES-003
Issue05 incl. FCC part 15

Version: 01/2018
Theodor-Heuss-Straße 4
D-37412 Herzberg am Harz
Phone [phone]
Fax [phone]
[email protected]
www.akkuteam.de