CAR-connect VAS 5581A User manual

21.VW.2210.3063_BA_V00_EN
VAS 5581A
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Operating manual
Diagnostic box VAS 5581A

21.VW.2210.3063_BA_V00_EN
VAS 5581A
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Revision Date Reason
V00 02.06.2021 First edition
Legal notice
Legal notice
Manufacturer CAR-connect GmbH
Am Egelingsberg 8
38542 Leiferde, Germany
Phone: [phone]
Fax: [phone]
[e-mail]
www.car-connect.cc
Reproduction Reproduction or reprinting, whether in whole or in part, always requires the written permission of
the manufacturer.
Copyright TRANSLATION OF THE ORIGINAL OPERATING MANUAL
All rights reserved.
All text, images and graphics are subject to copyright and other intellectual property laws.
Copyright 2020 CAR-connect GmbH.
Image sources Symbols for warnings, prohibitions, mandatory actions and standards are taken from publicly
accessible sources, such as the Internet. CAD product images and product photos are provided by the
manufacturer. Images showing the product in use are provided with a reference to the source.

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Contents
Contents
LEGAL NOTICE 2
CONTENTS 3
INTRODUCTION 5
Preliminary information 5
Validity of the declaration of conformity 5
Manufacturer specifications 5
SAFETY 6
Warning levels 6
Important safety instructions 7
Safety functions 8
Emergency stop button 8
Intended use 9
Requirements for the target group 10
Duties of the operator 10
Additional documents 10
PRODUCT DESCRIPTION 11
Scope of delivery 11
Design 12
Diagnostic box VAS 5581A/16 12
Power supply cable VAS 622 007 13
Adapter cable VAS 5581A/11 14
Sets 14
Symbols and connections 15
Displays and controls 17
Displays 17
Controls 18
Pin assignments 18
Technical data 19
OPERATION 20
Preparations 21
Preparing the diagnostic box 21
Switching on the diagnostic box 22
Connecting the power supply / Charging battery packs 23
Using the LC display 24
Buttons 24
Control keys 24
Menu structure 26
Operating mode menu 26
Settings menu 27
Information menu 28

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Contents
Operating modes 29
Soft bridge mode 29
Gateway mode 30
Hard bridge mode 31
Starting diagnostics 32
Connecting vehicle components 32
Activating power supply to the component 33
Configuring the connection 34
Closing the high-voltage relay 34
Setting the CAN termination resistor 35
Connecting the VC interface 35
Finishing diagnostics 36
Exiting diagnostics 36
Switching off the diagnostic box 36
Detaching the plug connections 37
Detaching the plug connection for the diagnostic cable (32-pin) 37
Cleaning 38
Storage and transportation 38
Disposal 38
Maintenance 39
Changing the Li-ion battery pack 39
HELP 43
Warranty 43
Customer service 43

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EN | Introduction
Introduction
Preliminary information
Read through this operating manual carefully before using the product.
The product is delivered with a USB stick containing the operating manual in various
languages. You can find the current version and additional languages on our homepage.
There is a QR code on the product. You can scan this QR code with a device that is connected
to the internet to go directly to the download area for your product.
A power supply from another manufacturer is included with the product. This has a separate
operating manual.
All operating manuals are an essential part of the product and must be kept together with
the product. If you sell or transfer ownership of the product, the operating manuals must be
handed over to the new operator.
In addition to the operating manuals, all the relevant regulations for working with traction
batteries in electric vehicles are binding. They include but are not limited to: instructions
from the vehicle manufacturer and the operator, company-specific safety requirements and
the latest engineering standards for working with electric vehicles.
Validity of the declaration of conformity
The declaration of conformity applies to the product described in the operating manual. Any
changes, modifications or extensions shall void the declaration of conformity and the risk
assessment.
Manufacturer specifications
CAR-connect GmbH
Since its founding, our company has focused on groundbreaking solutions for
electromobility. CAR
-
connect develops and produces custom solutions for the automotive
industry, repair shops and special vehicle fleets.
Our core business is developing and producing innovative high
-
voltage charging technology
for electric vehicles. Our portfolio also includes measurement and diagnostic technology for
the entire vehicle and battery analysis equipment.
With extensive experience in software and hardware development, CAR
-
connect is your
dependable partner at every
production stage, from prototyping to series production.
CAR-connect GmbH – Experience, Expertise and Innovation – MADE IN GERMANY

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EN | Safety
Safety
This safety chapter provides information about the following:
•The warning levels contained in this operating manual
•Important safety instructions for the product
•Intended use of the product
•Requirements for the target group
This operating manual is only valid for the following product:
Item number
See the “Sets” chapter.
Designation
Diagnos
tic box VAS 5581A
Warning levels
This chapter provides information about the warning levels used in this operating manual.
DANGER
Failure to observe the safety instructions WILL result in death or serious injury!
WARNING
Failure to observe with the safety instructions CAN result in death or serious injury!
CAUTION
Failure to observe the safety instructions CAN result in minor physical injury!

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EN | Safety
Important safety instructions
This chapter contains the safety instructions that must be observed when handling the
product.
DANGER
Danger of fatal electric shock!
The electrical voltage in other systems is lethal and will cause death by electric shock!
•Do not use the product for measurements on utility power circuits!
•
Never attempt to power other devices with the product!
WARNING
Danger of fatal electric shock!
The electrical voltage in high-voltage systems is lethal and can cause death by electric
shock!
Liquids, condensation and high humidity can cause short circuits!
•Do not let the product come into contact with liquids!
•
Use the product only in dry and enclosed spaces!
WARNING
Danger of fatal electric shock!
The electrical voltage in the product is dangerous and can cause serious injury or death
from electric shock!
Defective and damaged products cannot guarantee protection against electrical voltage!
•Do not let the product come into contact with chemicals!
•Replace a defective or damaged product immediately!
•
Never attempt to repair or tamper with the product!

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EN | Safety
Safety functions
Emergency stop button
WARNING
Danger due to impaired safety function!
Damage to the emergency stop button can impair the product’s safety function!
•Check the function of the emergency stop button at regular intervals (see the
“Pressing the emergency stop button” and “Maintenance” sections)!
•Make sure that the emergency stop button is always readily accessible!
The product is equipped with an emergency stop button. Pressing the emergency stop button
immediately stops the following:
1. The power supply to the diagnostic box
2. The electrical connection to terminals 15, 30 and the pilot line and thus the electrical
supply to the component being tested
3. Communication via the VC interface
4. The electrical connection to the universal power supply
Position Description
1 Emergency stop button

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EN | Safety
Pressing the emergency stop button
Push in the emergency stop button until it clicks into place.
All electrical connections are immediately interrupted.
Resetting the emergency stop button
1. Switch off the diagnostic box at the main switch (see chapter “Switching off the
diagnostic box”).
2. Turn the emergency stop button clockwise and pull out until it clicks into place.
Power supply to the diagnostic box is restored. You can now switch the diagnostic box
on again (see chapter “Switching on the diagnostic box”).
If you press the emergency stop button, the current diagnostics will be interrupted and
cannot be resumed. Error messages may appear in the diagnostic program.
Intended use
The diagnostic box is a tool for performing diagnostics on components outside the vehicle
network (stand-alone components).
The diagnostic box supplies the power to the component and has an OBD port for
establishing communication. This enables you to use diagnostic systems (e.g. ODIS Service in
combination with VC interface VAS 6154) that usually access components via the OBD
connector in the vehicle.
Depending on your requirements, the diagnostic system and the VC interface can
communicate with the stand-alone component in three different operating modes:
•Soft bridge mode (SB)
•Gateway mode (GW)
•Hard bridge mode (HB)
Connect the diagnostic box to the vehicle component you want to test using adapter cables.
The diagnostic box can be updated, allowing it to be adapted to future applications with a
firmware update. The diagnostic box is downward compatible with its predecessor the VAS
5581 and the corresponding adapter cables.
Use only the power supply belonging to the diagnostic box with the power supply cable
suitable for the country of use, and use only the rechargeable batteries belonging to the
diagnostic box (see chapters “Scope of delivery” and “Configuration”). Observe the operating
manual from the manufacturer of the power supply! Use only the plug connections on the
vehicle that the manufacturer has specified in the guided fault finding.
In this operating manual, vehicle manufacturers are exclusively defined as vehicle
manufacturers in the Volkswagen Group.
Any use beyond what is listed here is prohibited.

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EN | Safety
Requirements for the target group
Only qualified personnel may work with this product!
In this operating manual, qualified personnel is defined as personnel meeting the
requirements prescribed by the vehicle manufacturer for the Guided Fault Finding in the
respective country of operation.
Duties of the operator
The operator is responsible for ensuring that all staff working with the diagnostic box fulfills
the requirements for the target group.
Furthermore, the operator is responsible for ensuring the following:
•The diagnostic box is always in perfect working order.
•The regular inspection intervals for the diagnostic box are observed and recorded.
Additional documents
In addition to this document, the following documentation is also included with the product:
•Spare parts page, printed document 21.CC.2210.3063_ET
•Manufacturer’s documentation for universal power supply

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EN | Product description
Product description
Scope of delivery
Immediately check the condition of the product and the completeness of the delivery. If
anything is missing or defective, please contact the manufacturer immediately.
(1) Carrying case
(2) Diagnostic box VAS 5581A/16 with shock guard
(3) Adapter cable VAS 5581A/11
(4) Universal power supply VAS 5581A/10
(5) Power supply cable (country-specific, see chapter “Power supply cable”)
(6) USB stick with operating manual

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EN | Product description
Design
Diagnostic box VAS 5581A/16
Product design:
(1) Main switch
(2) USB 2.0 port (type B)
(3) Li-ion battery pack VAS 5581A/9 (in the diagnostic box)
(4) Emergency stop button
(5) Warning indicators
(6) OBD port
(7) LC display
(8) CAN port (A)
(9) Ethernet/LIN port (B)
(10) Power supply socket
(11) Control keys
(12) Status display

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EN | Product description
Power supply cable VAS 622 007
The product is delivered with a power supply cable suitable for the country of use. The ASE
number in parentheses is for the power supply cable with the corresponding plug. The power
supply cable has the following design, depending on the country of use:
(1) Power supply plug
(2) Power supply plug type F (EU – ASE 622 007 00 000)
(3) Power supply plug type H (IL – ASE 622 007 00 079)
(4) Power supply plug type G (UK – ASE 622 007 00 020)
(5) Power supply plug type B (USA – ASE 622 007 00 023/JP – ASE 622 007 00 070)
(6) Power supply plug type J (CH – ASE 622 007 00 004)
(7) Power supply plug type I (CN – ASE 622 007 00 074/AUS – ASE 622 007 00 026)
(8) Power supply plug type M (ZA – ASE 622 007 00 030)
(9) Power supply plug type N (BRA – ASE 622 007 00 066)

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EN | Product description
Adapter cable VAS 5581A/11
(1) Ground clip
(2) Low-voltage plug for MEB battery
(3) Plug for diagnostic box
Sets
The diagnostic box is delivered as a set with a country-specific power supply cable. The
following table shows the CC item numbers for the various sets.
CC item no. Standard parts Power supply cable ASE number
22102608
•Diagnostic box VAS
5581A/16
•Shock guard
•Adapter cable VAS
5581A/11
•Carrying case
•Universal power supply
•USB stick with operating
manual
Type F (EU)
409 040 71 000
22102871 Type J (CH) 409 040 71 004
22102872
Type G (UK)
409 040 71 020
22102873
Type B (US)
409 040 71 023
22102874
Type I (AUS)
409 040 71 026
22102875
Type M (ZAF)
409 040 71 030
22103066
Type N (BRA)
409 040 71 066
22103067
Type B (JP)
409 040 71 070
22103068
Type I (CN)
409 040 71 074
22103069
Type H (IL)
409 040 71 079

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EN | Product description
Symbols and connections
The product is equipped with the following stickers:
Position Description Function
1 Front sticker The front sticker shows the displays and controls.
2 Nameplate The nameplate is located below the shock guard
and contains the following information:
•Manufacturer information
•Product type
•Serial number
•Year of manufacture
•Degree of protection
•Power supply specifications
You can use the serial number to track information
relating to production.
3 Port labels The following stickers identify the adjacent ports:
•A: CAN port
•
B: Ethernet/LIN port

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EN | Product description
The following symbols are shown on the product stickers:
Symbol Meaning
When this symbol is illuminated, it means the high-voltage relay to the vehicle
component being tested is energized.
When this symbol is illuminated, the diagnostic box is communicating without galvanic
isolation.
The serial number is used in conjunction with the manufacturer part number to identify
the product.
22103063 The manufacturer part number is used in conjunction with the serial number to identify
the product.
Read the operating manual!
The disposal instructions prohibit disposal of the product with household waste. Always
dispose of the product in accordance with all local disposal regulations.
This marking indicates that the product must not be operated outdoors.
The CE marking certifies that the product complies with all applicable European
regulations and has been subjected to the prescribed conformity assessment procedure.
The test seal identifies the product as having been approved for use in workshops and
production facilities belonging to the vehicle manufacturer.
QR code for accessing the operating manual on mobile devices.

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EN | Product description
Displays and controls
The product is equipped with the following displays and controls:
Displays
Position Description Function
2 High voltage warning
light
Indicates that the high-voltage relay to the vehicle
component being tested is energized.
3 Isolation warning
light
Indicates that the diagnostic box is communicating
without galvanic isolation.
4 LC display •Display operating status
•Control device functions
•
User interface to the diagnostic box
6 “Pilot” status
indicator
LED illuminated: the pilot line is closed.
7 Terminal 30 status
indicator
LED illuminated: power supply to terminal 30 (+
battery voltage) is active.
8 Terminal 15 status
indicator
LED illuminated: power supply to terminal 15
(ignition) is active.

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EN | Product description
Controls
Position Description Function
1
Main switch
Switch the product on and off.
5 Control keys Direction keys: navigate within functions.
“OK” key: select or deselect functions.
9 Emergency stop
button
Immediately interrupt the power supply. The exact
function of the emergency stop button is described
in the “Safety” section.
Pin assignments
Pin CAN Ethernet LIN OBD
1
CAN 1 high
Ethernet TX +
Terminal 15 (ignition)
2
CAN 1 low
Activate Ethernet
—
3
CAN 2 high
Ethernet TX -
Ethernet TX +
4 CAN 2 low Ethernet RX + Terminal 31 (vehicle
ground)
5 Terminal 15 (battery +) Ethernet RX - Terminal 31 (vehicle
ground)
6 Terminal 31 (battery -) LIN GND CAN High (high-speed
CAN)
7
Terminal 30 (battery +)
LIN VDD (power supply)
—
8 Terminal 30C (battery +) LIN Signal —
9
Pilot IN
Terminal 15 (battery +)
—
10
Pilot OUT
Terminal 31 (battery -)
—
11 — Terminal 30 (battery +) Ethernet TX -
12
—
Terminal 30C (battery +)
Ethernet RX +
13
—
Pilot IN
Ethernet RX -
14 — Pilot OUT CAN Low (high-speed
CAN)
15
—
—
16 — — Terminal 30 (+ battery
voltage)

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EN | Product description
Technical data
Rated data Values
Manufacturer number
22103063
Input voltage
DC 18 – 24 V
Input current
Max. 2 A
Output voltage
DC 13.4 V
Output current
5 A
Batteries
6x Li-ion batteries, type 18650 (3000 mAh)
Battery voltage
DC 12.4 V
Degree of protection
IP20
Weight
With batteries: ~ 1070 g, without batteries: ~ 560 g
Dimension L/W/H
~ 220 mm/155 mm/65 mm
Ambient conditions Operation Storage/transport
Temperature Charging: 0 °C to 45 °C
Discharging: -20 ° to
60 °C
Max. 7 days: -20 °C to 65 °C
Max. 3 months: -20 °C to 40 °C
Max. 1 year: -20 °C to 25 °C
Relative humidity
35% to 85%
Condensation not permitted. Maximum permissible relative humidity: 60% in
environments with corrosive gas/air.

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EN | Operation
Operation
This section provides information about the following activities:
•Preparations
•Using the LC display
•Operating modes
•Starting diagnostics
•Finishing diagnostics
•Cleaning
•Storage
•Maintenance
WARNING
Danger of fatal electric shock!
The electrical voltage in other systems is lethal and can cause death by electric shock!
•
Use the product only for the applications intended by the vehicle manufacturer!
CAUTION
Risk of damage!
Products can be damaged if they fall.
•Be sure never to throw or drop the product!
•Only use the product with the included shock guard!