VOLKSWAGEN VAS6606/26 Adapter cable
Operating manualAdapter cable VAS 6606/26
| Revision | Date | Reason |
| V00 | 10.03.2021 | First edition |
| V01 | 17.03.2021 | Complete revision |
Legal notice
Manufacturer:CAR-connect GmbHAm Egelingsberg 838542 Leiferde, GermanyPhone: +49 (0) 5373 92197-0Fax: +49 (0) 5373 92197-88[email protected]www.car-connect.cc
ReproductionReproduction or reprinting, whether in whole or in part, always requires the written permission of the manufacturer.
CopyrightTRANSLATION 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 sourcesSymbols 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.
Introduction
Preliminary informationRead 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.The operating manual is 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 manual must be handed over to the new operator.In addition to this operating manual, you must observe all relevant regulations for diagnostics or troubleshooting of intrinsically safe high-voltage systems in road vehicles. This includes but is not limited to: instructions for the vehicle manufacturer’s diagnostics systems, company-specific safety requirements and the state of the art for working with high-voltage systems.
Validity of the declaration of conformityThe 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 GmbHSince 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
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 22102720Designation Adapter cable VAS 6606/26
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!
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!
Intended use
The product is used together with the VAS 6606 isolator box to test cell modules in MEB traction batteries as part of the diagnostics prescribed by the vehicle manufacturer.The product is suitable for the following diagnostics:
- Measuring the cell voltage
- Reading out the temperature sensors
The product is not used to test that the circuit is de-energized.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.
Requirements for the target group
Only qualified personnel may work with this product!In this operating manual, qualified personnel is defined as personnel meeting all requirements for working on high-voltage systems applicable in the country of operation, as defined by:
- Regulations applicable in the country of operation
- Qualification according to DGUV 200-005 level 2 or higher, or equivalent
- Specifications from the vehicle manufacturer and/or the operator.
At all times while using the product, staff must wear the personal protective equipment prescribed by the vehicle manufacturer for work on high-voltage systems.
Duties of the operator
The operator is responsible for ensuring that all staff working with the adapter cable fulfills the requirements for the target group.Furthermore, the operator is responsible for ensuring the following:
- The adapter cable is always in perfect working order.
- The regular inspection intervals for the adapter cable are observed and recorded.
Product description
Scope of deliveryImmediately check the condition of the product and the completeness of the delivery. If anything is missing or defective, please contact the manufacturer immediately.
- Adapter cable
- USB stick with operating manual
Product design:
- Plug for battery module
- Plug for isolator box
Symbols and connectionsThe following symbols are shown on the product:
Wiring diagram
Technical data
| Rated data | Values |
| Manufacturer number | 22102720 |
| Maximum rated voltage | Max. DC 60 V |
| Maximum rated current | 1 A |
| Weight | ~ 330 g |
| Total length | 2000 mm |
| Ambient conditions | Operation | Storage | Transportation |
| Temperature | 5 °C to 40 °C | -20 °C to 60 °C | -20 °C to 60 °C |
| Elevation above sea level | Max. 2000 m | No limitation. | |
| Humidity | Max. 80 % up to 31° C, decreasing linearly to 50 % at 40° C | Max. 85 % | |
| Condensation not permitted. Maximum permissible relative humidity: 60 % in environments with corrosive gas/air. |
Operation
This chapter provides information about the following activities:
- Startup
- Detaching the plug connection
- Cleaning
- Disposal
- Maintenance
WARNING: Danger of electric shock!
Energy storage devices CANNOT be de-energized.The electrical voltage in the battery modules is dangerous and can cause serious injury or death from electric shock!• Exercise extreme caution when working on open battery modules!
CAUTION: Danger of electric shock!
The electrical voltage in the product is dangerous and can cause mild injury from electric shock!• Use the product only for the applications intended by the vehicle manufacturer!
CAUTION: Risk of damage!
Plug connections lock into place when attached.• Unlock the plug connections before you detach them! (See chapter “Detaching the plug connections”)
Startup
- Observe the safety instructions.
- Connect the plug to the disconnected socket of the battery module you want to test.
- Connect the plug for the isolator box to the appropriate slot on the VAS 6606 isolator box.
- Push the lever up. This pulls the plug into the plug connection.
You can now perform measurements in accordance with the guided fault finding.
Detaching the plug connections
Detaching the isolator box plug (66-pin)The plug connection has a locking mechanism. To release the plug connection:
- Push the lever down. This releases the plug connection.
- Pull the plug connection apart.
The plug connection is now detached.
Detaching the battery module plugThe plug connection has an automatic locking mechanism. To release the plug connection:
- Push in and hold the locking mechanism.
- Pull the plug connection apart.
The plug connection is now detached.
Cleaning
WARNING: Danger of electric shock!The electrical voltage in the product is dangerous and can cause death by electric shock!• Disconnect the product from all power sources before cleaning the product!
Observe the safety instructions!Use only a dry cloth to clean the product.
DisposalObserve the safety instructions!Always dispose of the product in accordance with all local disposal regulations.
Maintenance
Observe the safety instructions!National and local requirements for regular testing must be observed!Test the product for proper function at intervals of no more than 24 months.Contact the manufacturer to have a professional function test performed.
Warranty
CAR-connect GmbH grants a warranty period of 24 months from the date of purchase. The warranty is valid for demonstrable defects in functional material and workmanship.Further information on the warranty conditions can be found in the terms and conditions on the manufacturer’s website.
Customer service
Always include the serial number with any product queries. This number is found on the product.
CAR-connect GmbHAm Egelingsberg 838542 Leiferde, GermanyPhone: +49 (0) 5373 – 92197-0Fax: +49 (0) 5373 – 92197-88[email protected]www.car-connect.cc
Volkswagen AktiengesellschaftK-GVO-LWGroup After Sales – Group ServiceLiterature and SystemsRepair Shop EquipmentPO box 011/491538442 Wolfsburg, Germany
For internal use onlySubject to technical changesEdition 03 / 2021
References
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