Volkswagen VAS 6910 User manual

Module-Balancer VAS 6910
Operating manual V10.00
11/18

Content
VAS 6910 hardware operating manual V10.00 11/18 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................................................................................1-4
1.6 Field of application.......................................................................................1-4
2COMPONENTS.............................................................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 0002-16
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
3COMMISSIONING.........................................................3-1
3.1 Firmware-Update.........................................................................................3-1
4OPERATION .................................................................4-1
4.1 Preparation..................................................................................................4-1
4.1.1 Charging / Discharging....................................................................4-1
4.1.2 Safety test.....................................................................................4-10
4.1.3 Self-test.........................................................................................4-12
4.1.4 Deviceinfo.....................................................................................4-14
4.1.5 Viewing all reports.........................................................................4-16

Content
VAS 6910 hardware operating manual V10.00 11/18 All rights reserved.
II
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
5TROUBLESHOOTING..................................................5-1
6MAINTENANCE AND CARE........................................6-1
6.1 Optical check...............................................................................................6-1
6.2 Cleaning ......................................................................................................6-1
7TECHNICAL DATA.......................................................7-1
7.1 Operating data.............................................................................................7-1
8FAULT REPORT FAX...................................................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 6910/5
ASE 447 231 00 000 AVL ID-Nr.: AT7784GB Rev. 10

Safety instructions
VAS 6910 hardware operating manual V10.00 11/18 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 6910 hardware operating manual V10.00 11/18 All rights reserved.
ii
WARNING
Read all instructions.
WARNING
Requirements needed to operate this device:
- High-voltage technician (HVT)
- High-voltage expert (HVE)
- Electrically qualified person for high-voltage systems in vehicles
- Electrician for special tasks on high-voltage systems in vehicles.
If you don’t have any of these qualifications please exit this application
immediately!
WARNING
Danger of flashing arcs
Never disconnect wirings while charging or discharging.
Opening the cover stops charging / discharging immediately!
WARNING
Use only as described in this manual.
Use only the referenced accessories from AVL DiTEST! See chap. 2.2 and 2.4.
WARNING
Use the included mains cord set (power cord)!
If the mains cord set has to be changed note the following requirements strictly!
On 240 V mains grid the mains cord set must be designed for a continuous current
of 10 A, on 120V mains grid the mains cord set must be designed for a continuous
current of 20 A.
The mains cord set must have a C19 plug for the connection to the VAS6910
suitable for the above current ratings.
Connect VAS 6910 only to protective contact sockets!
Set up the VAS 6910 in a way that there is always free access to the power
separator!!
(Power cord from the mains socket).

SICHERHEITSHINWEISE
VAS 6910 hardware operating manual V10.00 11/18 All rights reserved.
iii
WARNING
Do not operate equipment with a damaged cord or if the equipment has been
dropped or damaged –until it has been examined by a qualified service person.
WARNING
Do not let cord hang over edge of table, bench or counter, or come in contact with
hot manifolds or moving fan blades.
WARNING
An extension cord is not allowed. For testing use only specified cables.
WARNING
To reduce the risk of fire, do not operate equipment in the vicinity of open
containers of flammable liquids (gasoline).
WARNING
Risk of explosions
The VAS 6910 has internal parts which emit sparks and therefore must not be
exposed to flammable fumes. The VAS 6910 should be operated at least 460 mm
(18 inches) above the floor surface since fumes from fuels and other materials
accumulate at floor level.
WARNING
Connecting non-VW HV-Modules
The VAS 6910 has been developed for vehicles from the Volkswagen group.
Connecting the VAS 6910 directly to HV-Modules from other manufacturers can
therefore result in damage to the modules and / or the VAS 6910.
WARNUNG
Set up the VAS 6910 so that adequate ventilation is guaranteed, fans and air vents
are not obstructed and the air must circulate freely!

SICHERHEITSHINWEISE
VAS 6910 hardware operating manual V10.00 11/18 All rights reserved.
iv
WARNUNG
When connecting the cell module, make sure the IR temperature sensor is
not covered and ensure direct visibility between the sensor and the module.
CAUTION
The VAS 6910 may only be used within the measurement ranges stipulated in the
technical data and descriptions in the operating manual. Do not perform
measurements on damaged leads.
CAUTION
Cleaning
Before cleaning the VAS 6910, pull out the USB cable and measuring cables!
Clean the VAS 6910 only with a dry cloth. Do not use cleaners or solvents.
READ ALL INSTRUCTIONS - SAVE THESE INSTRUCTIONS!

SAFETY INSTRUCTIONS
VAS 6910 hardware operating manual V10.00 11/18 All rights reserved.
v
IMPORTANT SAFETY INSTRUCTIONS
1. Read all instructions.
2. Care must be taken as burns can occur from touching hot parts.
3. Do not operate equipment with a damaged cord or if the equipment
has been dropped or damaged - until it has been examined by a
qualified serviceman.
4. Do not let cord hang over edge of table, bench or counter or come in
contact with hot manifolds or moving fan blades.
5. If an extension cord is necessary, a cord with a current rating equal
to or more than that of the equipment should be used. Cords rated
for less current than the equipment may overheat. Care should be
taken to arrange the cord so that it will not be tripped over or pulled.
6. Always unplug equipment from electrical outlet when not in use.
Never use the cord to pull the plug from the outlet. Grasp plug and
pull to disconnect.
7. Let equipment cool completely before putting away. Loop cord
loosely around equipment when storing.
8. To reduce the risk of fire, do not operate equipment in the vicinity of
open containers of flammable liquids (gasoline).
9. Adequate ventilation should be provided when working on operating
internal combustion engines.
10. Keep hair, loose clothing, fingers, and all parts of body away from
moving parts.
11. To reduce the risk of electric shock, do not use on wet surfaces or
expose to rain.
12. Use only as described in the manual. Use only manufacturer´s
recommended attachments.
13. ALWAYS WEAR SAFETY GLASSES. Everyday eyeglasses only
have impact resistant lenses, they are NOT safety glasses.
SAVE THESE INSTRUCTIONS

General Information
VAS 6910 hardware operating manual V10.00 11/18 All rights reserved.
1-1
1 General Information
1.1 General Notes
The Module Balancer VAS 6910, here after named VAS6910, is able to charge and
discharge single cell modules of high voltage batteries from E-cars and hybrid cars.
To guarantee an overall equal load of all cell modules on a HV-battery, the new cell
module has to be charged / discharged to meet this load of the whole battery.
The conditioned „balanced“ cell module replaces the defect cell module.
The VAS6910 is designed to use in car shops which have to do HV battery repairs.
To use this device you must have a special qualification. See below.
Please follow the regulation valid to your country!
Read this operating manual and follow especially the safety hints!

General Information
VAS 6910 hardware operating manual V10.00 11/18 All rights reserved.
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.