CAR-connect High-Voltage Testing Adapter VAS 6558A/40 User Manual
- June 7, 2024
- CAR-connect
Table of Contents
CAR-connect High-Voltage Testing Adapter VAS 6558A/40 User Manual
Document identification
Imprint
Concept
The high-voltage testing adapter has been developed according to the latest
regulations in measurement and control technology, for use on intrinsically
safe high-voltage systems in road vehicles. The testing adapter corresponds
with the state of the art and meets all relevant European standards as well as
partially meets international standards.
Despite high standards for development, production and quality, only careful
handling and proper use can ensure that there is no damage and resulting
consequences. For this reason, this operating manual should be read and
understood in full.
Read the operating manual
Read this operating manual thoroughly before using the high-voltage testing
adapter. In this operating manual, the intended use and hazards of handling
the product are described.
In addition to this operating manual, other regulations may be binding for
diagnosis or troubleshooting of intrinsically safe high-voltage systems in
road vehicles. These include, among other things, the manuals of the vehicle
manufacturer as well as the instructions of the employers’ liability insurance
association.
Please ensure that all information on the product and its scope of application
is available to you before you use the high-voltage testing
adapter. Please use the adapter cable only if you have fully understood all
information pertaining to its use.
Structure of the document
For a better understanding of the information contained in this operating manual, additional descriptive pictograms are used. These markings indicate particularly relevant information and the images indicate the significance within a description or an operation step.
Therefore, please follow the instructions and information in this operating
manual, so that there is no bodily injury or property damage when used in the
high-voltage section of the vehicle.
The following table contains all the pictograms, warning symbols and symbols
that may appear in this manual.
Safety instructions
The basic safety instructions given below must be followed to avert bodily injury to people and property damage while using the high-voltage testing adapter.
General safety instructions
Most incidences of damage to property and personal injury are primarily due to ignorance or negligence and can be avoided from the outset if the following general safety instructions are observed:
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Read the operating manual carefully before use.
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Only people who can provide valid proof of technical knowledge of working on high-voltage systems in motor vehicles may perform
measurements on high-voltage systems. -
Follow the instructions in the guided troubleshooting, which is described in the PIWIS Tester.
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Use the high-voltage testing adapter only in closed and dry rooms.
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Follow the instructions of the trade association or government institutions for the repair of hybrid- and all-battery electric vehicles.
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Check the testing adapter regularly before use in accordance with the specifications of VDE 0701-0702:2010-08 (draft EN 62638).
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Use the testing adapter solely for the intended use, as specified by the vehicle manufacturer.
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Use the product solely for its intended purpose.
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Immediately replace a defective or damaged product.
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Never attempt to modify or manipulate the testing adapter.
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Never attempt to supply current or voltage to other devices through the testing adapter.
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Never use a test lamp or any other incompatible testing equipment to perform no-voltage checks on the testing adapter.
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Never attempt to repair a testing adapter.
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Do not use aggressive liquids to clean the product.
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Prevent the adapter cable from coming in contact with aggressive operating fluids such as brake fluid and coolant.
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Prevent the product from falling on the floor.
Intended use
The high-voltage testing adapter VAS 6558A/40 is a passive, non-selfindicating measuring device used in conjunction with the high-voltage measuring module VAS 6558A for diagnosis of high-voltage systems of road vehicles. With this measuring equipment combination, the deenergised state of the high-voltage system can be determined in a qualified and safe manner. The testing adapter makes the high-voltage connector (TE-HVP800) touch-protected on both sides and thus enables potential resistance and insulation resistance measurement. In doing so, please follow the work instructions in the PIWIS Tester.
Improper use
Any use of the product deviating from the intended use is considered improper use. Use of a manipulated or defective testing adapter will be considered in exactly the same way as disregarding or disobeying the instructions of the operating manual. This behaviour, in addition to limiting the guarantee and the loss of warranty claims, can also lead to bodily injury to people or damage to property under certain circumstances.
Obligations of the operator
The operator must ensure that appropriate and capable staff is appointed by
them to work on vehicle-specific high-voltage system. The proof of
qualification required for this is based on successful participation in
appropriate training. The operator must ensure that the measuring equipment
and accessories are in a faultless condition and they do not have any defects.
Regular inspection periods for the measuring equipment, accessories and
testing adapters are set out in an instruction manual. Also, it is the
operator’s responsibility to note the replacement of the high-voltage testing
adapter on reaching the number of operation cycles. The operator must ensure
that servicing staff regularly participate in refresher training courses for
repairs of high-voltage systems and pass these successfully as well.
User’s qualifications
The user has proven expertise to carry out work on high-voltage systems of fully battery-operated, plug-in hybrid or e-traction road vehicles. In addition, the user should have experience in taking cascade measurements, whereby active and passive measurements are taken simultaneously.
Transport
The product comes in recyclable disposable packaging, which is not suitable for storing the product after use.
Unpacking and checking for completeness
Check the condition and completeness of the contents based on the shipping
documents and the delivery note. In case of any damage or
defective components, contact the manufacturer immediately.
Fig. 1: Scope of supply of VAS 6558A/40
Transport during normal working hours
The high-voltage testing adapter is used along with the measuring module VAS 6558A and should be transported after diagnosis in a suitable transport container. Please ensure that moisture and metal dust do not enter the container
Safekeeping and storage
In order to avoid damage to the high-voltage testing adapter or to prevent the loss of accessories, always keep the measuring equipment in a transport case. This approach ensures a quick overview of a completed task, for example, if all the parts are once again placed in the case in the designated places.
High-voltage testing adapter
The high-voltage testing adapter VAS 6558A/40 is a passive, non-self-
indicating measuring unit used to certifiably determine the absence of voltage
in the high voltage system of road vehicles manufactured by Volkswagen.
For this, the testing adapter is adapted to the high-voltage connector TE-
HVP800 in a deenergised vehicle which has a lockable high-voltage cable
connector installed. The installed high-voltage cable connector is designed in
such a way that a two-way contact of the high-voltage connector is possible.
Fig. 2: Front and back with
cable connector
A suitable mating connector for the high-voltage connector is present on the high-voltage testing adapter. The vehicle-mounted high-voltage cable is attached to it and this cable is fixed and connected by flipping the locking lever. The highvoltage testing adapter is designed in such a way that it is not possible to touch the active high-voltage and low-voltage contacts while taking measurements. For personal protection, 100 kOhm resistors are attached to the laboratory test sockets HV (-) and HV (+) inside the testing adapter.
To carry out the specified measurements on the high-voltage systems, additionally the high-voltage measuring module VAS 6558A is used. The measuring module is used as per the guided troubleshooting instructions in the PIWIS tester. The laboratory sockets located on the sides of the testing adapter can be used with the measuring module or with another measuring device approved by the vehicle manufacturer for carrying out potential- and insulation measurement and to check the absence of voltage, as well as contacting the pilot lines.
Fig. 3: Side views of TP1 and
TP2
The high-voltage testing adapter VAS 6558A/40 consists of a two-part, screwed
plastic housing. The two dimensionally stable and accurate housing halves are
joined together almost seamlessly, which helps protect against splash water
and dripping water.
The plastic material used makes the housing resistant to impacts typically
encountered in everyday use, plays a repellent function against aggressive
substances and prevents a static charge thanks to its composition. The smooth,
non-porous and glossy surface minimises dust adhesion and thereby reduces the
effort required in cleaning.
The high-voltage test cables, which are permanently installed in the housing,
have kink protection on the housing side and the opposite ends of the cable
merge in a splash-proof vehicle-specific plug-in housing.
With this connector housing, the high-voltage connector (TE-HVP800) can be
contacted on both sides, since the connector has no side coding. Voltage
reversal coding is integrated. For the potential- and insulation measurement,
the test sockets are found on the sides of the test area TP1. The test sockets
of the pilot lines are installed in test area TP2 on the opposite side of the
housing.
Product labelling
Some product labels are attached to the testing adapter. The following tables describe each label and explain the signs shown.
The side label TP1 shows the plug-in connectors and their labels.
Fig. 4: TP1 marking
General warning regarding handling of the device is given on the back.
Fig. 5: Warning on the back of the device
The machine nameplate contains the following symbols and signs.
Fig. 6. Machine plat 6
The circuit diagram on the testing adapter shows the connections from the
high-voltage contacts to the plug-in connectors.
Fig. 7: Circuit diagram on the back of the device
The TP2 label contains the following symbols and signs.
Fig. 8: TP2 marking
Technical specifications
Operation
Before you can start testing the high-voltage components, ensure that the vehicle is de-energised. Follow the instructions given in the guided diagnostics of the vehicle manufacturer. Additionally, observe the following safety rules.
Insert the high-voltage testing adapter
The high-voltage testing adapter is inserted and used as per the vehicle manufacturer’s specifications. Follow the handling instructions in the guided software-aided vehicle diagnostics of the relevant brand of the company
Maintenance/self-testing
INFORMATION:
In addition to this operating manual, also read the operating instruction on the topic of maintenance/self-testing from the vehicle’s manufacturer and operator.
Maintenance of the device
No provisions are made by the device manufacturer for maintenance of the high- voltage testing adapter.
ATTENTION:
A separate measuring equipment test, in which safety-relevant components and functions are tested according to national or official specifications, can be commissioned by the operator or the vehicle manufacturer.
Recurring testing of the device.
To comply with the requirements for electrical safety of electrical equipment and work equipment in accordance with VDE 0701-0702: 2008 (draft EN 62638), the corresponding test instructions for an annual inspection are available on the manufacturer’s homepage.
INFORMATION:
See www.car-connect.cc/downloads for the required test instructions for your product.
Clean the device
The high-voltage testing adapter should only be cleaned with a dust-
absorbing cloth made of antistatic material. The testing adapter must
never come into contact with liquid cleaners, aggressive cleaning agents
or water in any form (splash water, dripping water, high-pressure cleaning
water).
Immediately replace the testing adapter, if it comes in contact with liquids
or chemicals.
Disposal
Note:
The product must not go into domestic waste at the end of its working
life. The operator of the high-voltage testing adapter is the owner
responsible for disposal according to the applicable European law and bears
the responsibility for appropriate disposal.
If other laws governing the disposal or recycling of electrical appliances
have priority regarding validity and application, these country-specific
regulations are binding for the process.
Product life cycle
DANGER:
The product life cycle of the high-voltage testing adapter is coupled with the operating cycles in which it is adapted to the high-voltage system. With more than 2000 cycles, the testing adapter must be replaced and must not be used any longer.
Environmentally responsible waste disposal
As soon as the testing adapter’s life cycle come to an end, it must be sent for sorted disposal. The testing adapter’s operator bears the responsibility for this as the owner responsible for disposal. The sale or gratuitous licensing for the purpose of disposal must be documented.
Customer service
Should you have any questions about the product, or wish to know the procedure for replacement or exchange deliveries, or simply wish to place an order, then contact the Customer Services at:
CAR-connect GmbH
Celler Str. 117
D-38518 Gifhorn
Telephone: +49 (0) 5373 – 92197- 0
Fax: +49 (0) 5373 – 92197-88
info@car-connect.cc
www.car-connect.cc
References
- Connect Christian Church | East Side of Cincinnati Near Withamsville, Eastgate, Amelia, Bethel, Batavia, Anderson
- Car Connect – Ihr Partner für Elektromobilität
- Downloads – Car Connect
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