The document describes the Diagnostic cable VAS 5581A/11, a specialized tool for automotive diagnostics, specifically designed for high-voltage systems in Volkswagen vehicles.
Function Description
The VAS 5581A/11 diagnostic cable serves as an adapter to connect the VAS 5581A high-voltage diagnostic box to the vehicle-side plug connection specified by the vehicle manufacturer during guided fault finding. Its primary function is to facilitate the testing of the high-voltage battery by connecting to the battery management system. The product is intended for use only on high-voltage systems that have been certifiably de-energized. It is specifically suitable for testing the high-voltage battery in the Volkswagen ID.3 (2020 model). Any use beyond this specified application is prohibited.
The diagnostic cable is an essential component for ensuring safe and accurate diagnostics of intrinsically safe high-voltage systems in road vehicles. It is designed to meet the stringent safety requirements and technical specifications for working with high-voltage systems in the automotive industry.
Important Technical Specifications
The diagnostic cable VAS 5581A/11 has the following key technical specifications:
- Manufacturer number: 22102779
- Maximum rated voltage: DC 14 V
- Maximum rated current: 5 A
- Weight: Approximately 300 g
- Cable length: Approximately 2000 mm/1500 mm (likely referring to different cable segments or total length)
Ambient Conditions:
- Operation Temperature: 5 °C to 40 °C
- Storage Temperature: -20 °C to 60 °C
- Transportation Temperature: -20 °C to 60 °C
- Elevation above sea level: Maximum 2000 m (for operation)
- Humidity (Operation): Maximum 80% up to 31°C, decreasing linearly to 50% at 40°C. Condensation is not permitted.
- Humidity (Storage/Transportation): Maximum 85%
- Maximum permissible relative humidity: 60% in environments with corrosive gas/air (for operation).
The product complies with protection class II, indicating increased or double insulation between active and accessible parts, in accordance with VDE 0100, Part 410/412.1. It also bears the CE marking, certifying compliance with applicable European regulations, and a test seal indicating approval for use in workshops and production facilities of the vehicle manufacturer.
Usage Features
The operating manual emphasizes strict adherence to safety instructions and proper usage procedures.
Startup:
- Safety First: Always observe all safety instructions before connecting the device.
- Ground Connection: Connect the ground clip to a conductive part of the vehicle body.
- Low-Voltage Plug Connection: Connect the low-voltage plug to the disconnected socket of the MEB battery intended for testing.
- Locking Mechanism: Fold the locking mechanism up until it clicks into place, ensuring the plug is securely pulled into the connection.
- Lock Button (Optional): Press the lock button in (if required, though noted as "not required" in one step, suggesting it might be an additional safety feature or context-dependent).
- Diagnostic Box Connection: Connect the plug to the diagnostic box.
Once connected, measurements can be performed in accordance with the guided fault finding procedures.
Detaching Plug Connections:
The plug connections feature a locking mechanism to prevent accidental disconnection. To detach a plug connection:
- Pull out the lock button.
- Press down the latch and fold down the locking mechanism until it clicks into place. This action releases the plug from the connection.
- Pull the plug connection apart.
It is crucial to unlock the plug connections before detaching them to prevent damage.
Safety Warnings:
- DANGER - Fatal Electric Shock: The product must not be used for measurements on utility power circuits or to power other devices. Electrical voltage in high-voltage systems is lethal.
- WARNING - Fatal Electric Shock: The product must not come into contact with liquids, condensation, or high humidity, as these can cause short circuits. It should only be used in dry and enclosed spaces. Defective or damaged products must be replaced immediately and never repaired or tampered with.
- WARNING - Risk of Explosion: Product components may produce sparks and electric arcs. The product must not be used in potentially explosive atmospheres.
- CAUTION - Risk of Damage: Always ensure plug connections are unlocked before detaching them.
- CAUTION - Adapter Cable: Always check the VAS number to ensure a suitable adapter cable is being used.
Target Group Requirements:
Only qualified personnel are permitted to work with this product. Qualified personnel are defined as individuals meeting all requirements for working on high-voltage systems in the country of operation, including:
- Compliance with local regulations.
- Qualification according to DGUV 200-005 level 2 or higher, or equivalent.
- Adherence to specifications from the vehicle manufacturer and/or operator.
Personal protective equipment prescribed by the vehicle manufacturer for high-voltage work must be worn at all times.
Duties of the Operator:
The operator is responsible for ensuring that all staff using the diagnostic cable meet the target group requirements, that the cable is always in perfect working order, and that regular inspection intervals are observed and recorded.
Maintenance Features
Cleaning:
- DANGER - Fatal Electric Shock: Disconnect the product from all power sources before cleaning.
- Only use a dry cloth to clean the product. Do not use liquids or chemicals.
Storage:
- Store the product in a dry and dust-free location when not in use to prevent damage and maintain its integrity.
Disposal:
- The product must not be disposed of with household waste. Always dispose of the product in accordance with all local disposal regulations.
Maintenance and Testing:
- Observe all safety instructions related to maintenance.
- National and local requirements for regular testing must be observed.
- The product should be tested for proper function at intervals of no more than 24 months.
- Contact the manufacturer (CAR-connect GmbH) to have a professional function test performed.
Warranty:
CAR-connect GmbH provides a 24-month warranty from the date of purchase, covering demonstrable defects in functional material and workmanship. Further details on warranty conditions are available on the manufacturer's website.
Customer Service:
For any product queries, always include the serial number, which is found on the product.
CAR-connect GmbH
Am Egelingsberg 8
38542 Leiferde, Germany
Phone: +49 (0) 5373-92197-0
Fax: +49 (0) 5373-92197-88
Email: service@car-connect.cc
Website: www.car-connect.cc
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