Volkswagen VAS 6911A User manual

Leakagetester VAS 6911A
Operating Manual V9.00
12/19

Content
VAS 6911A Operating Manual V9.00 12/19 All rights reserved.
I
Content
SAFETY INSTRUCTIONS..........................................................I
1GENERAL 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................................................................................1-5
1.6Field of application.......................................................................................1-5
2COMPONENTS AND MODE OF OPERATION............2-1
2.1 VAS 6911A Front View................................................................................2-1
2.2VAS 6911A Rear View.................................................................................2-2
2.3 Cable Sets, Standard Delivery.....................................................................2-3
2.3.1 Set of Test Connector and Test Plug VAS 6911/3A, BO7969,
ASE 447 273 01 000 ............................................................................................. 2-3
2.3.2 Set of Sealing Plugs VAS 6911/4, BO7862, ASE 447 274 00 000....................... 2-4
2.3.3 Vacuum hose, VAS 6911/6A, BO7973, ASE 447 276 01 000 .............................. 2-5
2.3.4 Carrying case (Aluminum) VAS 6911/7, BG7456, ASE 447 277 00 000.............. 2-5
2.3.5 USB-Cable (USB 2.0 A to USB 2.0 B Rugged), VAS 611 001, EX7069,
ASE 611 001 00 000 ............................................................................................. 2-6
2.3.6 USB-Cable (USB 2.0 Fischer zo USB 2.0 B Rugged), VAS 611 003,
BV8139, ASE 611 03 00 000................................................................................. 2-6
2.4 Accessories .................................................................................................2-7
2.4.1 2D-Barcode Scanner VAS 6161/1, ASE 447 043 00 000 .................................... 2-7
2.4.2 Gas Leak Search Device VAS 6227, ASE 418 365 00 000.................................. 2-8
2.4.3 Leak Search Device VAS 6911/14, ASE 447 284 00 000..................................... 2-8
2.4.4 Rubber Stopper VAS 6911/10, ASE 447 281 00 000 .......................................... 2-8
2.5 Scpope of delivery.......................................................................................2-9
3START-UP.....................................................................3-1
3.1 Firmware-Update.........................................................................................3-1
4OPERATING .................................................................4-1
4.1 Preparation..................................................................................................4-1
4.1.1 Leakage Test......................................................................................................... 4-1
4.1.2 Selftest................................................................................................................. 4-13
4.1.3 Getting Device Info.............................................................................................. 4-16
4.1.4 Switch off............................................................................................................. 4-17

Content
VAS 6911A Operating Manual V9.00 12/19 All rights reserved.
II
5TROUBLESHOOTING..................................................5-1
6MAINTENANCE AND CARE........................................6-1
6.1 Optical check...............................................................................................6-1
6.2 Cleaning ......................................................................................................6-1
7TECHNICAL DATA.......................................................7-1
8SYSTEM DELIVERY - PROOF OF DELIVERY............8-1
9INDEX............................................................................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 6911A/1
ASE 447 271 00 000 AVL ID-Nr.: AT7791EN Rev. 09

Safety Instructions
VAS 6911A Operating Manual V9.00 12/19 All rights reserved.
i
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:
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.
Additional danger signal:
Danger due to electrical current.
Remarks:
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
VAS 6911A Operating Manual V9.00 12/19 All rights reserved.
ii
WARNING
Read all instructions.
WARNING
For contaminants caused by liquid or solid particles to pneumatic circuit and
resulting damage to pneumatic components as well as damage to pneumatic
components applying external pressure at the testconnector no guarantee or liability
can be granted. This applies also to consequential damages of test facilities or test
components.
WARNING
During leak test the connecting tube and test adapter must not be moved!
There must be no direct sunlight to the VAS 6911 and to the HV-battery!
The test object and the VAS 6911 must be conditioned to room temperature before
starting the test! Sufficient air ventilation at the backside of the VAS 6911 must be
assured! There must be no air draft!
WARNING
Use only as described in this manual. Use only manufacturer’s recommended
attachments.
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
Adequate ventilation should be provided when working on operating internal
combustion engines.

Safety Instructions
VAS 6911A Operating Manual V9.00 12/19 All rights reserved.
iii
WARNING
Risk of explosions
The VAS 6911A has internal parts which emit sparks and therefore must not be
exposed to flammable fumes. The VAS 6911A 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 6911A were developed for HV batteries of the Volkswagen group. It must
not be used in HV batteries from other manufacturers!
WARNING
Connect only to mains with protective conductor!
WARNING
Place the VAS6911A in that way, that you have access to the on/off switch at any
time!
WARNING
Make sure that (2) Ventilation, (3) Air out and (5) pump outlet isn’t blocked and air
can circulate!
WARNING
Replace power cord only by a new one with same specification, at least 0.75 mm²
cross section / ≤AWG 18!
CAUTION
The VAS 6911A 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 6911A, disconnect the power cord and the USB cable!
Use only a dry cloth for cleaning! Do not use any cleaner or solvent.
SAVE THESE INSTRUCTIONS!

IMPORTANT SAFETY INSTRUCTIONS
VAS 6911A Operating Manual V9.00 12/19 All rights reserved.
iv
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 equip-ment 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

Allgemeine Angaben
VAS 6911A Operating Manual V9.00 12/19 All rights reserved.
1-1
1 General Information
1.1 General Notes
The Leakage Tester VAS6911A, hereinafter called VAS6911A, can be used to check
the leakage of HV-Batteries used in Hybrid or E-Cars.
The VAS6911A was designed for use in Car-Shops / service stations or similar
Institutions.
It’s determined for professional, trained personnel.
WARNING
For contaminants caused by liquid or solid particles to pneumatic circuit and resulting
damage to pneumatic components as well as damage to pneumatic components ba
applying external pressure at the testconnector no guarantee or liability can be
granted. This applies also to consequential damages of test facilities or test
components.
WARNING
During leak test the connecting tube and test adapter must not be moved! There
must be no direct sunlight to the VAS6911 and to the HV-battery! The test object
must be conditioned to room temperature before starting the test! There must be no
draught.
WARNING
If accessories or the VAS6911A is damaged, do not use the VAS6911A until it’s
serviced!
Please follow the regulation valid to your country!
Read this operating manual and follow especially the safety hints!

Allgemeine Angaben
VAS 6911A Operating Manual V9.00 12/19 All rights reserved.
1-2
1.2 Safety Notes
Please observe the safety instructions for the VAS 6911A.
Sie befinden sich hinter dem Inhaltsverzeichnis.
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 3 years after its
delivery. Subsequent calibrations should be carried out every 12months.

Allgemeine Angaben
VAS 6911A Operating Manual V9.00 12/19 All rights reserved.
1-3
Dichtprüfgerät / Leakagetester VAS 6911A
Bestellnummer: BO7987
Das Dichtprüfgerät VAS 6911A wurde unter Einhaltung aller Vorgaben nach
der jeweils gültigen Prüfvorschrift erfolgreich getestet und hat in
einwandfreiem Zustand unser Haus verlassen.
In den ersten 12 Monaten nach der Auslieferung des Geräts ist keine
Kalibrierung erforderlich.
The Leakage Tester VAS 6911A 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 12 month after delivery of the device, calibration is not
required.
AVL ist nach ISO 9001 zertifiziert!
AVL is accredited according to ISO 9001!
AVL DiTEST GmbH - Alte Poststrasse 152 - 8020 Graz - AUSTRIA
Fig. 1-1 Certificate of Calibration

Allgemeine Angaben
VAS 6911A Operating Manual V9.00 12/19 All rights reserved.
1-4
1.4 Designated Use
The VAS 6911A may only be used in that way, described in this manual.
WARNING
The housing should only be opened by service personal. See Service Information,
Chap. 3.1 Regional Service partners).
WARNING
Connect only to mains with protective conductor!
WARNING
Place the VAS6911A in that way, that you have access to the on/off switch at any
time!
WARNING
Make sure that (2) Ventilation, (3) Air out and (5) pump outlet isn’t blocked and air
can circulate!
WARNING
Replace power cord only by one with same specification, at least 0.75 mm² cross
section / < AWG 18!
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 6911A.

Allgemeine Angaben
VAS 6911A Operating Manual V9.00 12/19 All rights reserved.
1-5
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 6911A:
Unpacking instructions, start-up, brief instructions VAS 6911A
Registration Certificate
Service Information
1.6 Field of application
The VAS6911A is designed to check the leakage of HV-Batteries used in Hybrid or
E-Cars.

Components and mode of operation
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2-1
2 Components and mode of operation
2.1 VAS 6911A Front View
Fig. 2-1 VAS 6911A, front view
(1) Handle
(2) LED blue Device in stand by
(3) LED red Leakage test in progress or error occurred
(4) LED green no leakage test active
(5) Handle
(6) Ventilation opening for cooling by fresh air.
(7) Ventilation opening for cooling by fresh air.
(8) Ventilation opening for cooling by fresh air.
(9) Vacuum hose connection
WARNING
Make sure that (6), (7), (8) Ventilation isn’t blocked and air can circulate!
9 8 7 6
1 2 3 4 5

Components and mode of operation
VAS 6911A Operating Manual V9.00 12/19 All rights reserved.
2-2
2.2 VAS 6911A Rear View
Fig. 2-2 VAS 6911, rear view
(1) USB connection
(2) Ventilation
(3) Nameplate
(4) Vent
(5) Option: air in for leakage search
(6) Pump outlet
(7) Warning plate
(8) Mains connection (powercoord connector, on/off switch and fuses)
WARNING
Connect only to mains with protective conductor!
Do not bring the mains cable in contact with the floor!
Place the VAS6911A in that way, that you have access to the on/off switch at any
time!
Make sure that (2) Ventilation, (3) Air out and (5) pump outlet isn’t blocked and air
can circulate.
For continued protection against risk of fire, replace only with the same type! (T4A /
250 VAC)
8 7 6 5 4 3
1 2

Components and mode of operation
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2-3
2.3 Cable Sets, Standard Delivery
2.3.1 Set of Test Connector and Test Plug
VAS 6911/3A, BO7969, ASE 447 273 01 000
The set consists of the Test Plug eUp!, eGolf, Golf GTE, A3 e-tron and the Test
Connector eUp!, eGolf, Golf GTE, A3 e-tron.
2.3.1.1 Test Plug eUp!, eGolf, Golf GTE, A3 e-tron
VAS 6911/3A-1, EN7583
This test plug is used for leakage testing on VOLKSWAGEN eUP!, eGolf, Golf GTE
and A3 e-tron. The test plug is connecting to the traction plug of the HV-Battery.
Fig. 2-3 Test plug eUp!, eGolf, Golf GTE and A3 e-tron
2.3.1.2 Test connector eUp!, eGolf, Golf GTE, A3 e-tron
VAS 6911/3-2, EN7553
Der test connector is used for leakage testing of the VAS6911A with vaccum hose
and applied test plug (selftest).
Fig. 2-4 Test connector eUp!, eGolf, Golf GTE, A3 e-tron

Components and mode of operation
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2-4
2.3.2 Set of Sealing Plugs
VAS 6911/4, BO7862, ASE 447 274 00 000
The set consists of the Sealing Plug eUp! and the Sealing Plug eGolf.
2.3.2.1 Sealing Plug eUp!
VAS 6911/4-1, EN7555
The sealing plug is used for sealing of the “DC-Charging Connector“.
Fig. 2-5 Sealing Plug eUp
2.3.2.2 Sealing Plug eGolf
VAS 6911/4-2, EN7552
The sealing plug is used for sealing of the „DC-Charging connector“
Fig. 2-6 Sealing Plug eGolf

Components and mode of operation
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2-5
2.3.3 Vacuum hose, VAS 6911/6A, BO7973, ASE 447 276 01 000
The vacuum hose connects the VAS6911A to test connector compatible with the HV-
Battery.
Bild 2-7 Vacuum hose,
2.3.4 Carrying case (Aluminum) VAS 6911/7, BG7456, ASE 447 277 00 000
Used for transportation and storage of the VAS6911A.
Fig. 2-8 Carrying case (Aluminum)

Components and mode of operation
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2-6
2.3.5 USB-Cable (USB 2.0 A to USB 2.0 B Rugged),
VAS 611 001, EX7069, ASE 611 001 00 000
This cable is used if no Fischer connector is available at the VW Diagnostic system
Fig. 2-9 USB-Cable USB 2.0 A to USB 2.0 B Rugged
2.3.6 USB-Cable (USB 2.0 Fischer zo USB 2.0 B Rugged),
VAS 611 003, BV8139, ASE 611 03 00 000
This USB cable connects the VAS 6911A to the VW Diagnostic system.
Fig. 2-10 USB-cable USB 2.0 Fischer to USB 2.0 B Rugged

Components and mode of operation
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2-7
2.4 Accessories
Delivered by VOLKSWAGEN!
2.4.1 2D-Barcode Scanner
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. 2-11 2D-Barcodescanner

Components and mode of operation
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2-8
2.4.2 Gas Leak Search Device
VAS 6227, ASE 418 365 00 000
Delivered by VOLKSWAGEN.
Gas Detector for locating a leak. Used together with VAS6911/14.
2.4.3 Leak Search Device
VAS 6911/14, ASE 447 284 00 000
Delivered by VOLKSWAGEN.
This is a Gasbottle which is connected to the test plug.
Using this leakage search system the leakage of the HV-Batterie can be found easily.
This system works separately from the VAS 6911A.
Only the test plug is neccessary / used.
Before using this option please see the Volkswagen documentation.
Please notice the specific regulations and srandards in your country.
2.4.4 Rubber Stopper
VAS 6911/10, ASE 447 281 00 000
Delivered by VOLKSWAGEN
Used for sealing the over/ under pressure valves build in the HV-battery