vas 6558a high-voltage measuring module

VAS 6558A High-voltage measuring module

Hardware operating manual V1.07 07/19

Content

VAS 6558A hardware operating manual V1.07 07/19 All rights reserved. I

Content

SAFETY INSTRUCTIONS ......................................................................... I

IMPORTANT SAFETY INSTRUCTIONS ................................................ III

IMPORTANT NOTICES ....................................................................... VIII

1 GENERAL 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 Field of application ................................................................................................................ 1-5

2 COMPONENTS AND MODE OF OPERATION ........................ 2-1

2.1 Overview ............................................................................................................................... 2-1

2.2 Scope of delivery .................................................................................................................. 2-2

2.3 Power supply ......................................................................................................................... 2-4

2.4 Top ............................................................................................................................... 2-5

2.5 Workshop trolley ................................................................................................................... 2-6

2.6 Test adapter .......................................................................................................................... 2-7

2.7 Probe tips .............................................................................................................................. 2-8

2.8 USB adapter with cable relief ................................................................................................ 2-9

2.9 Fischer-to-USB Adaptor (optional) ........................................................................................ 2-9

3 OPERATION ............................................................................. 3-1

3.1 Switching on the VAS 6558A ................................................................................................ 3-1

3.2 Switching off the VAS 6558A ................................................................................................ 3-1

3.3 VAS 6556/VAS 6556A workshop trolley ............................................................................... 3-2

4 FIRMWARE-UPDATE ............................................................... 4-1

5 TROUBLESHOOTING .............................................................. 5-1

5.1 Introduction ........................................................................................................................... 5-1

5.2 Self-test ............................................................................................................................... 5-1

5.3 Error messages ..................................................................................................................... 5-2

5.4 VAS 6558A function test ....................................................................................................... 5-5

5.4.1 DC Voltage measurement ...................................................................................... 5-5

5.4.2 Insulation measurement according to SAE J1766 ................................................ 5-6

5.4.3 High voltage insulation measurement ................................................................... 5-7

5.4.4 Electrical Resistor Measurement ........................................................................... 5-8

5.4.5 Diode Test ............................................................................................................. 5-9

5.4.6 Equipotential Measurement ................................................................................. 5-10

5.5 Fault reports to customer service........................................................................................ 5-11

Content

VAS 6558A hardware operating manual V1.07 07/19 All rights reserved. II

5.6 Replacement parts and accessories ................................................................................... 5-12

5.6.1 Overview .............................................................................................................. 5-12

5.6.2 General notes ...................................................................................................... 5-13

5.6.3 VAS 6558A parts list ............................................................................................ 5-14

6 MAINTENANCE AND CARE .................................................... 6-1

6.1 VAS 6558A optical check ...................................................................................................... 6-1

6.2 Cleaning VAS 6558A ............................................................................................................ 6-1

6.3 Calibration ............................................................................................................................. 6-1

7 TECHNICAL DATA ................................................................... 7-1

7.1 Hybrid measuring module VAS 6558A ................................................................................. 7-1

7.1.1 Operating data ....................................................................................................... 7-2

7.2 Test instruments.................................................................................................................... 7-3

7.2.1 DC Voltage measurement ...................................................................................... 7-3

7.2.2 Insulation measurement according to SAE J1766 ................................................ 7-4

7.2.3 High voltage insulation measurement ................................................................... 7-5

7.2.4 Equipotential Measurement ................................................................................... 7-6

7.2.5 Electrical Resistor Measurement ........................................................................... 7-7

7.2.6 Diode Test ............................................................................................................. 7-8

8 TERMS ...................................................................................... 8-1

9 INDEX ........................................................................................ 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 A-8020 Graz AT7976DB Rev07

Content

VAS 6558A hardware operating manual V1.07 07/19 All rights reserved. III

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 6558A:

/1/ Unpacking instructions, start-up, brief instructions VAS 6558A with important information on start-up and registration of the device. This documentation is a component part of the scope of delivery

/3/ Operating manual VAS 6558A software. Description of the software with detailed information on the functioning of the test instruments. Operating manuals can be called up on the tester via the administration. They are located on the CD/DVD.

/4/ VAS 6558A service information contains important information, addresses and telephone hotllines in case of a fault.

In the running text a reference to the applicable documents appears as follows: Text.... (for further information see /4/).

Safety Instructions

VAS 6558A hardware operating manual V1.07 07/19 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.

The risk symbol requires highest attention for your safety.

Warning!

Texts with this symbol contain information relating to your safety and how you can reduce the risk of serious injuries.

The WARNING symbol requires particular attention for your safety.

Caution!

Texts with this symbol contain information on how you can avoid damage to the vehicle and the device.

The Caution symbol informs you that damage to the vehicle, tester, specified laptop or VAS 6558A could result if the information is being ignored.

Safety Instructions

VAS 6558A hardware operating manual V1.07 07/19 All rights reserved. ii

Note

Text with this symbol contains additional, useful information.

A Note symbol contains other, special instructions for using the device, and related information.

Note on further safety instructions

The general safety instructions, which are valid for the VAS 6558A, are listed in the following. Further safety instructions are to be found in the operating manuals. Therefore, please read the operating manuals before use. Safety instructions may also appear on the screen of the tester. Follow all the instructions displayed.

IMPORTANT SAFETY INSTRUCTIONS

VAS 6558A hardware operating manual V1.07 07/19 All rights reserved. iii


READ ALL INSTRUCTIONS - SAVE THESE INSTRUCTIONS!

1. Warning!

Use only as described in this manual. Use only manufacturer’s recommended attachments.

2. 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.

3. Danger!

The high voltage battery provides hazardous voltages. Make sure that nobody comes in contact with connections of the hybrid battery, connecting cables of the hybrid battery or other visible parts under high voltage.

4. Danger!

The VAS 6558A is not suitable for measurements on the power grid! The VAS 6558A is only suitable for measuring DC voltages! Any outlets installed in the vehicle must not be measured! Measurements with the VAS 6558A on electric vehicles may only be carried out if no charging cable is connected to the vehicle!


VAS 6558A hardware operating manual V1.07 07/19 All rights reserved. iv

5. Danger!

Do not touch the ends of test adapters and probe tips during high voltage insulation measurement.

If the ends of test adapters/probe tips are disconnected or are connected to an ohmic test object for measurement, then a current of up to 1 mA with a voltage of 250 … 1000 V would flow through your body if touched. The electrical shock is noticeable, however the electrical current does not reach fatal levels.

After high voltage insulation measurement, high voltage decreases on the probe tips. It is displayed on the VAS 5051B, VAS 5052A and VAS 6150 / VAS 6160 (specified laptop) as soon as the high voltage is decreased. Make sure that nobody comes in contact with the test adapters/probe tips as long as high voltage is applied!

6. Warning!

Only carry out the measurement of DC voltage-free with the hybrid voltage measuring adapter VAS 6558 / 1-1 *

For other measurements use the hybrid measurement adapter for leakage resistance measurement, VAS 6558A/1-2* or the hybrid measurement adapter for air conditioning compressor, VAS 6558A/1-3*.

In any case observe the user guidance of the software!

7. Warning!

The test object must be de-energised during high voltage insulation measurement. For this reason, carry out a voltage measurement before every high voltage insulation measurement! Make sure that the test object is de-energised during high voltage insulation measurement!

8. Danger!

Opening the VAS 6558A without permission, or making unauthorised modifications, can expose both yourself and the device to serious danger. *) Only used for VW Tuareg, Audi Q5, Porsche Cayenne and Porsche Panamera!

For VW Jetta use the VAS6558/9-X adaptors!


VAS 6558A hardware operating manual V1.07 07/19 All rights reserved. v

9. Warning!

Danger of tripping Do not let cord hang over edge of table, bench or counter, or come in contact with hot manifolds or moving fan blades. Pay attention to possible tripping hazards during the measuring process.

10. Warning!

An extension cord is not allowed. For testing use only specified cables.

11. Warning!

To reduce the risk of fire, do not operate equipment in the vicinity of open containers of flammable liquids (gasoline).

12. Warning!

Adequate ventilation should be provided when working on operating internal combustion engines.

13. Warning!

Risk of explosions The VAS 6558A has internal parts which emit sparks and therefore must not be exposed to flammable fumes. The VAS 6558A should be operated at least 460 mm (18 inches) above the floor surface since fumes from fuels and other materials accumulate at floor level.

14. Warning!

Care must be taken as burns can occur from touching hot parts.


VAS 6558A hardware operating manual V1.07 07/19 All rights reserved. vi

15. Warning!

Let equipment cool completely before putting away. Loop cord loosely around equipment when storing.

16. Warning!

Keep hair, loose clothing, fingers, and all parts of body away from moving parts.

17. Warning!

To reduce the risk of electric shock, do not use on wet surfaces or expose to rain.

18. Warning!

ALWAYS WEAR SAFETY GLASSES. Everyday eyeglasses only have impact resistant lenses, they are not safety glasses.

19. Caution!

The VAS 6558A 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.

20. Warning!

Electrical ignition systems have voltages up to approx. 30 kV. Observe general safety guidelines for workshops at all times.

21. Warning!

Fire hazard due to overheating Protect the VAS 6558A from direct sunlight and heat. Do not place the VAS 6558A on any heat sources. Place the VAS 6558A on a non-flammable, heat-resistant and non-conductive surface during the measurement process.


VAS 6558A hardware operating manual V1.07 07/19 All rights reserved. vii

22. Caution! when connecting non-VW vehicles!

The VAS 6558A has been developed for vehicles from the Volkswagen group. Connecting the VAS 6558 directly to vehicles from other manufacturers can therefore result in damage to the vehicle and / or the VAS 6558A.

23. Caution! when cleaning the VAS 6558A

Before cleaning the VAS 6558A, pull out the USB cable and measuring cables! Clean the VAS 6558A only with a dry cloth. Do not use cleaners or solvents.

READ ALL INSTRUCTIONS - SAVE THESE INSTRUCTIONS!

IMPORTANT NOTICES

VAS 6558A hardware operating manual V1.07 07/19 All rights reserved. viii

IMPORTANT NOTICES

1. Caution!

Please note the indications of the connected controller/PC/notebook/tester regarding contamination!

2. Caution!

If the VAS 6558A is used in a way we did not specify, the protection provided by the VAS 6558A may be impaired!

General Information

VAS 6558A hardware operating manual V1.07 07/19 All rights reserved. 1-1

1 General Information

1.1 General Notes

This operating manual contains the information required for the intended use of the high-voltage measuring module VAS 6558A, in the following referred to as "VAS 6558A". It is intended for qualified technical personnel who have the appropriate knowledge in the field of vehicle self-diagnosis and test instruments.

Knowledge and technically correct implementation of the safety instructions and warnings contained in this operating manual are the prerequisites for the safe starting-up of the VAS 6558A as well as for safety during operation and maintenance. Due to space limitations, this operating manual cannot cover all possible details regarding the Hardware1, nor does it cover every conceivable circumstance of start-up, operation, care or maintenance. Due to the overlapping validity of much of the information for the VAS 6558A, the operating manual has been divided into the following sections:

"Operating manual for VAS 6558A Hardware" (this document) and

"Operating manual for VAS 6558A Software" (description of the tester modes and the application on the vehicle), /3/.

1. The glossary arrow refers the reader to an explanation for the marked term in chapter 8.

General Information


1.2 Safety Notes

Please observe the safety instructions for the VAS 6558A. They are located on the rear of the device, in the operating manual (hardware and software) following the table of contents and at respective locations where they are relevant. Safety instructions specific to applications are also displayed directly at the VAS 6558A.

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 24 months, also refer to section 6.3.

General Information


Hochvolt-Messmodul VAS 6558A Bestellnummer: BO7777

Das Hochvolt-Messmodul VAS 6558A wurde unter Einhaltung aller Vorgaben nach der jeweils gültigen Prüfvorschrift erfolgreich getestet und hat in einwandfreiem Zustand unser Haus verlassen.

In den ersten 36 Monaten nach der Auslieferung des Geräts ist keine

Kalibrierung erforderlich.

Siehe mitgeliefertes Dokument „Calibration Protocol VAS 6558A“

The high-voltage measuring module VAS 6558A 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 36 month after delivery of the device, calibration is not

required.

Please see attached document „Calibration Protocol VAS 6558A“

AVL ist nach ISO 9001 zertifiziert!

AVL is accredited according to ISO 9001!

AVL DiTEST GmbH - Alte Poststrasse 156 - A-8020 Graz

Fig. 1-1 Certificate of Calibration

General Information


1.4 Designated Use

The VAS 6558A may only be used at a vehicle.

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 6558A.

General Information


1.5 Field of application

The VAS 6558A is used in conjunction with diagnostic testers VAS 5051B and 5052A and the specified laptop for measurement on modern vehicles with Electric-/Hybrid Drive.

Functions:

Initialisation/self-test

Measurement of DC voltage ( de-energised)

Measurement of insulation resistance

(Calculation of insulation resistance by measuring current and voltage)

Measurement of insulation resistance according to SAE J1766

(Measurement under load with parallel resistance)

Measurement of electrical resistors

Diode testing

Equipotential measurement

Features:

Parameterisation with adjustable test voltage: 250 … 1000 Volt , measuring current: 1 mA

Generation of high voltage is enabled only after pressing the button, automatic discharge of high voltage after the high voltage insulation measurement

Safety circuit for high voltage (automatic shutdown)

Function control with 2 LEDs

Combination of VAS 6558A with diagnosis testers VAS 5051B, VAS 5052A or a specified laptop VAS 6160

Interface between VAS 6558A and VAS 5051B, VAS 5052A or a specified laptop according to ASAM-GDI specification for ODIS

Power supply via USB interface, 5 Volt /500 mA

Interface: USB 2.0

Galvanic isolation against USB interface

Calibration using VAS 5143A calibration device

Software:

VASPC software (in connection to the guided error search GFS)

Integration into VOLKSWAGEN ODIS (Offboard Diagnostics Information System) with ASAM GDI driver.

Components and mode of operation


2 Components and mode of operation

2.1 Overview

The VAS 6558A consists of the following components

(1) High-voltage measuring module

(2) LEDs, blue and red/green

(3) Black probe tip for placing on the black test adapter

(4) Red probe tip for placing on the red test adapter

(5) Shock protection on the red test adapter

(6) Button on the red test adapter

(7) Red test adapter

(8) Shock protection on the black test adapter

(9) Black test adapter

(10) “Fischer” plug

(11) „Fischer-to-USB Adaptor“ (optional, see 2.2. Scope of delivery)

Fig. 2-1 VAS 6558A

7 6

10

9

1 2

5 8

3 4 11



2.2 Scope of delivery

There are several types of delivery. These are:

System delivery

Accessories supplied with the delivery

Deliverable accessories

Table 2-1 VAS 6558A scope of delivery

Components System delivery

Accessories supplied with the delivery

Deliverable accessories

VAS 6558A, High-voltage measuring module (complete) comprising:

VAS 6558A/2, High-voltage measuring module basic device

VAS 6558A/3, storage case

VAS 6558A/4, red probe tip**

VAS 6558A/5, black probe tip**

VAS 6558A/6 CD/DVD with: a) Software:

VAS 6558A software (driver) b) Documents:

Hardware operating manual

Service information

Registration certificate

Unpacking, start up and brief instructions

VAS 6558A/7, unpacking, startup and brief instructions (hard copy),registration certificate (hard copy)

VAS 6558A/24, red probe tip***

VAS 6558A/25, black probe tip***

VAS 6558A/--, 0ohm clip



VAS 5055/4 „Fischer-to-USB“-Adaptor (optional) The Adaptor VAS 5055/4 is needed for diagnostic testers which do not have a build in „Fischer“-socket for use as an USB port (i.e..: VAS 5051B, VAS 5052A, VAS 6150, VAS 6150A)

VAS 5055/2, USB adapter with cable relief

VAS 6558/1*, The hybrid measuring adapter set contains:

VAS 6558/1-1*, Hybrid measurement adapter for voltage measurement

VAS 6558/1-2*, Hybrid measurement adapter for leakage resistance measurement

VAS 6558/1-3*, Hybrid measurement adapter for air conditioning compressor

VAS 6558/9** Set HV-Test adaptor containing:

VAS 6558/9-1** Hybrid-Testadaptor single IPT

VAS 6558/9-2** Hybrid-Testadaptor 2-pole IPT

VAS 6558/9-3** Hybrid-Testadaptor 3-pole IPT

VAS 6558/9-4** Hybrid-Testadaptor for climate compressor



VAS 6558A/27, Set of Kelvin-clamps (red and black)

VAS 6558A/27-1, red Kelvin-clamp

VAS 6558A/27-2, black Kelvin-clamp

VAS 6558A/--, 0 ohm clip

VAS 6558A/24, Red probe tip***

VAS 6558A/25, Black probe tip***

*) Only for use on VW Tuareg, Audi Q5, Porsche Cayenne and Porsche Panamera! **) Needed for use on VW Jetta Hybrid, Audi Q5 Hybrid! ***) Used for VW Tuareg Hybrid, Audi Q7 Hybrid!

2.3 Power supply

The VAS 6558A is supplied with current via the USB interface.



2.4 Top

2 LEDs (1) and (2) are found on the top:

LED LED colour LED status Meaning

blue lights up Normal operating status

flashes slowly Error has occurred, error in normal operating status

flashes quickly Error has occurred, e.g. no firmware in the device.

green lights up Normal operating status. During execution of the sub tests the LED is changing it’s color from time to time to green or red.

flashes slowly Self-test is in progress

flashes quickly Waiting for a keypress to start the self test

red/green off Firmware is updated with bootloader

red

green

blue

lights up

off

lights up

A voltage > 10 V is applied on the test probes. (Measuring voltage or high voltage generated by the VAS 6558A)

Fig. 2-2 Front of VAS 6558A

!

(1)

(2)

1 2



2.5 Workshop trolley

The VAS 6558A is connected to the cable hooks of the VAS 6556/VAS 6556A workshop trolley.

Caution!

When operating with the workshop trolley, make sure that there is sufficient ventilation of the table power adapters for the printer and for the VAS 6556.

The heat dissipation of the table power adapter must not be blocked by articles placed on top (cables, rags, etc.).

Disconnect the power cable from the workshop trolley to switch off the entire device.

Fig. 2-3 VAS 6556/VAS 6556A workshop trolley with VAS 6558A



2.6 Test adapter

Warning!

Overvoltage categories CAT-II 600V / CAT-III 300V

The VAS 6558A fulfils impulse voltage values as per the overvoltage category II.

Measurements in electric circuits that are connected directly to the mains are not permitted!

For this reason use the VAS 6558A only for measurements on the vehicle.

Measuring cables are permanently connected to the test adapters and the VAS 6558A. The red test adapter has a button which can be used to switch on high voltage during high voltage insulation measurement. Fig. 2-4 Test adapter

Shock protection

Button (only on the red test adapter)

Test adapter

Cable



2.7 Probe tips

The Probe tips can be attached to the test adaptors.

Danger!

The Probe tips may be used for the Isolation-Measurement (SAE J1766 and High Voltage Isolation Measurement) only in conjunction with the Hybrid. Test Adaptors VAS6558/9-X.

Fig. 2-5 Test adapter with probe tips

Probe tips

Shock protection

Button (only on the red test adapter)

Test adapter

Cable



2.8 USB adapter with cable relief

The USB adapter with strain relief, approx. 25 cm long, is used for connecting the VAS 6558A to the VAS 5052A without docking station. The right angle plug and strain relief give increased bend protection and an improved strain relief for the USB plug. See /1/, unpacking, startup and brief instructions, chapter 4 Assembly, “Connecting the VAS 6558A to the VAS 5052A without docking station”. Fig. 2-6 USB adapter with right angle plug

2.9 Fischer-to-USB Adaptor (optional)

The „Fischer-to-USB“- Adapter 5055/4 is needed for the diagnostic testers VAS 5051B / VAS 5052A and for the specified Laptops VAS6150 / VAS 6150A / VAS 6160, because they do not have a “Fischer”-Socket usable as a USB-Port. Fig. 2-7 „Fischer-to-USB“-Adaptor

Operation


3 Operation

This chapter describes the operation of the VAS 6558A, provided that it does not concern operating the program via the tester or the specified laptop.

3.1 Switching on the VAS 6558A

The VAS 6558A does not have an on/off switch. As soon as the VAS 6558A is supplied with current via the USB interface, it begins a self-diagnosis and then goes into standby mode.

Note

Do not attempt to operate the VAS 6558A during startup.

3.2 Switching off the VAS 6558A

The VAS 6558A does not have an on/off switch. Disconnect the power supply of the VAS 6558A by unplugging the USB cable (or unplugging the “Fisher-plug”) from the tester/specified laptop.

Operation


3.3 VAS 6556/VAS 6556A workshop trolley

Fig. 3-1 VAS 6556/VAS 6556A workshop trolley The workshop trolley is used for mobile use of the VAS 6558 in the workshop. It is mounted on four wheels to allow it to be easily pushed within the working environment. All workshop trolleys are equipped with a dust-protective cover. It can be folded together during operation and stored in the storage compartment of the workshop trolley. Mobility

Both front wheels of the workshop trolley have been equipped with brakes to allow it to be fixed at its location. Release the brakes to move the trolley. You can push or pull the trolley to its new location using the grips on the left or right side. You can then lock the brakes at the new location.

Firmware-update


4 Firmware-update

Note

If necessary you can request an update of the VAS 6558A firmware after installation or update of the VASPC software.

1. Start the firmware update program by clicking “Start”, “Programs”, “DiTEST”,

“VAS6558A” and "VAS 6558A Firmware Update". The displayed screen will appear (fig 4-1).

2. Select your language and click "OK" (1).

Fig. 4-1 Firmware Update

3. Click "OK" (2). The latest data will be searched for.

Fig. 4-2 Firmware Update

2

1

Firmware-update


4. The files to be updated appear in the "Packet info and Update configuration" (3) area. Pay attention to the notes in the "Information" (4) area: - Connect your URDI-module to your VAS 6558A and press ‘OK’ button. - IMPORTANT: Do not disconnect the VAS 6558A from the USB Interface during the update!

Fig. 4-3 Firmware update, data packages

5. Click "OK" (5). Connection with the VAS 6558A is established.

Fig. 4-4 Firmware update, start update

6. Click "Start" (6) to start the update. The update can take a few minutes.

7. After the update has ended successfully, the "Update successful" message appears in the "Information" area (4).

3

4

5

6

4

Troubleshooting


5 Troubleshooting

The VAS 6558A has been fully tested before being dispatched from the factory. Carefully chosen components and adherence to numerous quality controls guarantee high reliability for the VAS 6558A. However, if a problem does occur then please read the instructions in this chapter before contacting the appropriate customer service (see /4/), Service information.

5.1 Introduction

Please try to determine what the fault is and to locate it as exactly as possible. Follow the suggestions for solving the problem and carry out all measures suggested when possible. If the fault can not be remedied by the measures provided here then follow the instructions in Section 5.3.

5.2 Self-test

During the "start-up", the VAS 6558A carries out a self-test. If you receive error messages after this self-test, please contact customer service. Refer to section 5.5.

Troubleshooting


5.3 Error messages

The possible error messages and corrective measures are listed below.

First of all, check proper connection of the VAS 6558A to the USB port of the diagnosis tester.

If required, disconnect the VAS6558A from the USB port of the diagnosis tester and reconnect after a few seconds again.

If the error persists, please contact the responsible hotline and state the exact error message. See /4/, service information, chapter 3.1 Regional services centres.

Table 5-1 Error messages and corrective measures/description

Error message Corrective measure/ description

The measuring mode is not initialised Restart the measuring mode, if necessary check that a ComPort or communication error has not occurred previously

Incorrect measuring mode Measurement in this measuring mode is incorrect or not possible Reset, if necessary

The measurement was aborted due to an error

Restart the measurement, if necessary check that a ComPort or communication error has not occurred previously

Thread timeout. The last action has not yet ended

If the system freezes, wait for the last action to terminate

-> End the application in the task manager and restart

An error occurred during the self-test Repeat self-test in case of sequential error or replace device in case of hardware error

An error occurred during calibration Repeat calibration

Incorrect measurement status Repeat measurement, reset if necessary

Invalid value Measured value is invalid, -> Repeat measurement

The value is outside the valid range set the correct measuring range and repeat measurement

Troubleshooting



Invalid parameter Parameter in the command is invalid, correct parameter accordingly

Check sum error Communication error (only for programmers)

A communication error has occurred Repeat command or reconnect, check that Comport is not blocked if error is repeated

An error has occurred at the serial interfaces Check that the COM port is not occupied by another application and close it. If necessary, terminate it in the task manager

An error occurred during programming of the flash memory

Repeat firmware update or check that a ComPort or communication error has not occurred previously

A communication error has occurred on EEProm

Device for service

A communication error has occurred in the firmware

Unplug and reinsert the device

A communication error has occurred while charging the test voltage

Resistance of test device too low, use high-resistance test device

A communication error has occurred while discharging the test voltage

in the hardware (replacement) or the device was connected incorrectly

Timeout The selection has timed out, please repeat the action

The waiting time for the keypress on the probe tips has expired

Repeat the measurement and press the button within 30 seconds

An error has occurred during the measurement process

Ditto reset or repeat the measurement depending on the error

The waiting time for the start of the measurement process has expired

Repeat measurement

An unknown command has been given Update the firmware/VASPC software

Troubleshooting



The given command is invalid or not permissible in the current measurement status

Repeat command in the right measure-ment status or repeat measurement

Incorrect version Update to the latest software version Other error Repeat last action and reset if necessary Null object Error or crash in the software

-> Restart software Amperage too high! Load resistance is too low

Troubleshooting


5.4 VAS 6558A function test

5.4.1 DC Voltage measurement

Carry out a function test of DC voltage measurement of the VAS 6558A as follows:

Measure a known DC voltage.

To do so, please observe / 3 /, software operating manual.

Troubleshooting


5.4.2 Insulation measurement according to SAE J1766

To carry out a function test of insulation measurement of the VAS 6558A according to SAE J1766, proceed as follows:

Check the VAS 6558A on an intact vehicle by performing an insulation measure-ment according to SAE J1766.


Troubleshooting


5.4.3 High voltage insulation measurement

Danger!

The high voltage battery provides hazardous voltages. Make sure that nobody comes in contact with connections of the high-voltage battery, connecting cables of the high-voltage battery or other visible parts under high voltage.

Danger!

Do not touch the ends of test adapters and probe tips during high voltage insulation measurement.

If the ends of test adapters/probe tips are disconnected or are connected to an ohmic test object for measurement, then a current of up to 1 mA with a voltage of 250 … 1000 V would flow through your body if touched. The electrical shock is noticeable, however the electrical current does not reach fatal levels.

After high voltage insulation measurement, high voltage decreases on the probe tips. It is displayed on the VAS 5051B, VAS 5052A and VAS 6150 (specified laptop) as soon as the high voltage is decreased. Make sure that nobody comes in contact with the test adapters/probe tips as long as high voltage is applied!

Warning!

The test object must be de-energised during high voltage insulation measurement. For this reason, carry out a voltage measurement before every high voltage insulation measurement! Make sure that the test object is de-energised during high voltage insulation measurement!

Carry out a function test of high voltage measurement of the VAS 6558A as follows:

Check the VAS 6558A on an intact vehicle by performing a high voltage measurement.


Troubleshooting


5.4.4 Electrical Resistor Measurement

Attention!

The test object must be de-energised during a resistor measurement. For this reason, carry out a voltage measurement before every resistor measurement! Make sure that the test object is de-energised during high voltage insulation measurement!

Danger!


Troubleshooting


5.4.5 Diode Test

Attention!

The test object must be de-energised during a diode test. For this reason, carry out a voltage measurement before every diode test! Make sure that the test object is de-energised during a diode test!

Danger!


Troubleshooting


5.4.6 Equipotential Measurement

Attention!

The test object must be de-energised during an equipotential measurement. For this reason, carry out a voltage measurement before every equipotential measurement! Make sure that the test object is de-energised during an equipotential measurement!

Danger!


Troubleshooting


5.5 Fault reports to customer service

If the test results do not match the required values then there is a fault in the VAS 6558A. In this case, please submit a fault report. For more information see /4/, service information, chapter 3.1 Regional service centres.

Troubleshooting


5.6 Replacement parts and accessories

5.6.1 Overview

During the guarantee period, repairs to the VAS 6558A are made by replacing defined components. In case of submitting a fault report to your appropriate customer service you will be informed which components will be replaced under guarantee conditions. You will then receive one or more replacement parts on the instigation of the guarantor. These parts are divided into exchange parts and replacement parts.

Exchange parts: Some components of the VAS 6558A are exchange parts that you must return in exchange for a new or repaired component. You will be told the address to send the defective exchange parts to as required. The components sent can also be replaced by a repaired exchange part. You are not entitled to receive new parts.

Replacement parts: You can dispose of replacement parts yourself. Please observe your national regulations on the disposal of such parts.

Section 5.6.3 lists all parts and informs you of whether a particular part is an exchange part, a replacement part or a repair part.

Troubleshooting


5.6.2 General notes

VAS 6558A

The measuring cables with test adapters and the USB cable are permanently connected to the VAS 6558A. If the VAS 6558A must be replaced, please use the box in which you receive your a replacement device to return the defective device. Return the entire VAS 6558A, but first remove the accessories. (CD/DVD, unpacking, start-up, brief instructions and the registration certificate). VAS 6556/VAS 6556A workshop trolley

To obtain spare parts for the VAS 6556/VAS 6556A workshop trolley, please contact the manufacturer (Knürr, see /4/, service information).

Troubleshooting


5.6.3 VAS 6558A parts list

Table 5-2 Symbols and abbreviations

Identification Meaning

A Exchange part

E Replacement part

Troubleshooting


no. Designation Version

VA

S n

o.

Ord

er

nu

mb

er

Su

pp

lier

Typ

e

Syste

m

delivery

Accesso

ries

1 VAS 6558A High-voltage measuring module (complete) comprising:

6558A

405 3

50 0

1 0

00

AV

L D

iTE

ST

A

2 VAS 6558A/2 High-voltage measuring module basic device

6558A

/2

405 3

55 0

1 0

00

AV

L D

iTE

ST

A

3 VAS 6558A/3 storage case

6558A

/3

405 3

56 0

1 0

00

AV

L D

iTE

ST

E

4 VAS 6558A/4** red probe tip

6558A

/4

40

5 3

57 0

0 0

00

AV

L D

iTE

ST

E

5 VAS 6558A/5** black probe tip

6558A

/5

405 3

58 0

0 0

00

AV

L D

iTE

ST

E

Troubleshooting



VA

S n

o.

Ord

er

nu

mb

er

Su

pp

lier

Typ

e

Syste

m

delivery

Accesso

ries

6 VAS 6558A/6 CD/DVD with: a) Software:

VAS 6558A software (driver) b) Documents:

Hardware operating manual

Service information

Registration certificate

Unpacking, start-up and brief instructions

6558A

/6

405 3

59 0

1 0

00

AV

L D

iTE

ST

E

7 VAS 6558A/7 unpacking, start-up and brief instructions (hard copy), registration certificate (hard copy)

6558A

/7

405 3

60 0

1 0

00

AV

L D

iTE

ST

E

8 VAS 6558A/24 red probe tip***

6558A

/24

405 3

91 0

0 0

00

VO

LK

SW

AG

EN

E

9 VAS 6558A/25 black probe tip***

6558A

/25

405 3

92 0

0 0

00

VO

LK

SW

AG

EN

E

10 VAS 6558A/-- 0 ohm clip

6558A

/--

AV

L D

iTE

ST

E

Troubleshooting



VA

S n

o.

Ord

er

nu

mb

er

Su

pp

lier

Typ

e

Syste

m

delivery

Accesso

ries

11 VAS 5055/2 USB adapter with cable relief (VE 2 pieces)

5055/2

405 2

57 0

0 0

00

VO

LK

SW

AG

EN

E

12 VAS 5055/4 „Fischer-to-USB“-Adapter (optional)

5055/4

405 2

58 0

0 0

00

VO

LK

SW

AG

EN

E

13 VAS 6558/1* The hybrid measuring adapter set contains 14 … 16

6558/1

405 3

51 0

0 0

00

VO

LK

SW

AG

EN

E

14 VAS 6558/1-1* Hybrid measurement adapter for voltage measurement

6558

/1-1

405 3

52 0

0 0

00

VO

LK

SW

AG

EN

E

15 VAS 6558/1-2* Hybrid measurement adapter for leakage resistance measurement

6558/1

-2

405 2

352 0

0 0

00

VO

LK

SW

AG

EN

E

Troubleshooting



VA

S n

o.

Ord

er

nu

mb

er

Su

pp

lier

Typ

e

Syste

m

delivery

Accesso

ries

16 VAS 6558/1-3* Hybrid measurement adapter for air conditioning compressor

6558/1

-3

405 3

54 0

0 0

00

VO

LK

SW

AG

EN

E

17 VAS 6558/9** Set HV Test Adaptors containing pos. 18..21

6558/9

405 3

62 0

0 0

00

VO

LK

SW

AG

EN

E

18 VAS 6558/9-1** Hybrid Test Adaptor single IPT

6558/9

-1

405 3

63 0

0 0

00

VO

LK

SW

AG

EN

E

19 VAS 6558/9-2** Hybrid Test Adapter 2-pole IPT

6558/9

-2

405 3

64 0

0 0

00

VO

LK

SW

AG

EN

E

20 VAS 6558/9-3** Hybrid- Prüfadapter 3-pole IPT

6558/9

-3

405 3

65 0

0 0

00

VO

LK

SW

AG

EN

E

Troubleshooting


no. Designation Delivery

VA

S-N

o.

Ord

er-

No

.

Po

rvid

er

Typ

e

Sta

nd

ard

Deli

very

Op

tio

nal

Accesso

ry

21 VAS 6558/9-4** Hybrid Test Adaptor for used on the climate compressor

6558/9

-4

405 3

66 0

0 0

00

VO

LK

SW

AG

EN

E

22 VAS 6558A/27 Set of Kelvin-clamps (red and black)

6558A

/27

405 3

94 0

00 0

0

VO

LK

SW

AG

EN

E

23 VAS 6558A/27-1 red Kelvin-clamp

6558A

/27-1

405 3

71 0

00 0

0

VO

LK

SW

AG

EN

E

24 VAS 6558A/27-2 black Kelvin-clamp

6558A

/27

-2

405 3

72 0

00 0

0

VO

LK

SW

AG

EN

E

Troubleshooting


no. Designation Delivery

VA

S-N

o.

Ord

er-

No

.

Po

rvid

er

Typ

e

Sta

nd

ard

Deli

very

Op

tio

nal

Accesso

ry

25 VAS 6558A/-- 0 ohm clip

6558A

/--

---

---

-- -

--

AV

L D

iTE

ST

E

26 VAS 6558A/24 Red probe tip***

6558A

/24

405 3

91 0

00 0

0

VO

LK

SW

AG

EN

E

27 VAS 6558A/29 Black probe tip***

6558A

/25

405 3

92 0

00 0

0

VO

LK

SW

AG

EN

E

*) Used for VW Tuareg, Audi Q5, Porsche Cayenne and Porsche Panamera! **) Used for VW Jetta Hybrid, Audi Q5 Hybrid! ***) Used for VW Tuareg Hybrid, Audi Q7 Hybrid!

Maintenance and care


6 Maintenance and care

6.1 VAS 6558A optical check

Carry out a regular optical check of the VAS 6558A, USB cable and measuring cables with the test adapters. Check for damage and dirt.

Warning!

If the VAS 6558A, the USB cable or measuring cables with probe tips are damaged, do not use them until they have been checked and approved by a properly qualified technician.

.

6.2 Cleaning VAS 6558A

Caution!

Before cleaning the VAS 6558A, pull out the measuring cables and the USB cable! Clean the VAS 6558A only with a dry cloth. Do not use cleaners or solvents.

If the VAS 6558A is damaged, please contact the AVL DiTEST hotline (see /4/, service information, chapter 2.2 VAS 6558 high-voltage measuring module).

6.3 Calibration

According to ISO regulations 9000 ff., the measurement accuracy of all measuring equipment that influences the quality of the work carried out (in this case, maintenance and repair work) must be periodically calibrated. The VAS 6558A and the measurement cable is calibrated for 3 years on delivery (see section 1.3). Thereafter, calibration must be repeated every 24 months. Before this time has expired, please consult your relevant service centre, see /4/, service information, chapter 3.1 Regional service centres.

Technical data


7 Technical data

7.1 Hybrid measuring module VAS 6558A

Warning!

The VAS 6558A is not suitable for measurements on the power grid! The VAS 6558A is only suitable for measuring DC voltages! Any outlets installed in the vehicle must not be measured! Measurements with the VAS 6558A on electric vehicles may only be carried out if no charging cable is connected to the vehicle!

Measurement CategoriesVAS 6558A

CAT I / Equipment without a rated measurement category up to 1000 V:

Means that the test equipment can measure voltages of up to 1000 V in electric vehicles. The appliance is not suitable for direct connection to a supply mains! CAT II / 600V:

Means that the test equipment can withstand transient overvoltages of up to 4000 V. CAT III / 300V:

Means that the test equipment can withstand transient overvoltages of up to 4000 V.

Technical data


7.1.1 Operating data

Dimensions (B x L x H) 95 x 220 x 45 mm

Weight approx. 0.5 kg

Ambient requirements operation Transport and storage

Ambient temperature Relative humidity Max. altitude Ambient temperature Relative humidity

0 to +40°C at max. +25°C 10 to 80 % non-condensing 4000m -20 to +55°C at max. +20°C 10 to 80% non-condensing

Electrical protection and storage

Safety regulations - DIN EN 61010-1 + DIN EN 61010-2-030 - IEC 61010-1 + IEC 61010-2-030 - VDE 0411-1 - UL 201 GARAGE EQUIPMENT

VAS 6558A/2 high-voltage measuring module: - Degree of protection: IP 44 (housing) - Pollution degree II - Overvoltage categories CAT II / 600V CAT III / 300V

This product has been tested to the requirements of CAN/CSA-C22.2 No. 61010-1, second edition, including Amendment 1, or a later version of the same standard incorporating the same level of testing requirements.

Supply from the USB interface Rated voltage Current consumption Protection

5 V max. 500 mA The input is protected against reversed polarity.

External interfaces, wired 1xUSB via „Fischer“-

Connector 2 x measurement cables

1 x USB 2.0 standard

Warning!

The VAS 6558A High Voltage Measurement Module is only suitable for Measuring of DC-Voltages! The VAS6558 has no AC-Measuring Ranges! Measurements on electric vehicles may only be carried out if no chargers are connected!

Technical data


7.2 Test instruments

7.2.1 DC Voltage measurement

Warning! during measurement of the voltage

Overvoltage categories CAT II / 600V, CAT III / 300V

The VAS 6558A fulfils impulse voltage values as per the overvoltage categories CAT II / 600V, CAT III / 300V.

Measurements in electric circuits that are connected directly to the mains are not permitted! For this reason use the VAS 6558A only for measurements on the vehicle.

DC voltage (Ri ≥ 1 MΩ)

Range: Resolution: Tolerances: -20 to +20 V 0.01 V ± 0.5 % v. M. 1 ± 5 digits -100 to +100 V 0.1 V ± 1.0 % v. M. ± 5 digits -1000 to +1000 V 0.5 V ± 1.5 % v. M. ± 5 digits

1. from measured value

The internal resistance can be adjusted by a connectable, variable, electronic resistor within a range of 100 kOhm up to 500 kOhm.

Using this feature the Voltage measurements can be done under load.

Technical data


7.2.2 Insulation measurement according to SAE J1766

Warning! during insulation measurement according to SAE J1766


The VAS 6558A fulfils impulse voltage values as per the overvoltage categories CAT II / 600V, CAT III / 300V.



Insulation measurement according to SAE J1766

Range: Resolution: Tolerances: 0 to 1000 MOhm 10 kOhm ± 1.5 % v. M. 1


Technical data


7.2.3 High voltage insulation measurement

Warning! during high voltage insulation measurement


The VAS 6558A fulfils surge voltage values as per the overvoltage categories CAT II / 600V, CAT III / 300V.

Measurements circuits that are connected directly to the mains are not permitted!


High voltage insulation measurement

Range: Resolution: Tolerances: 0 to 1000 MOhm 10 kOhm ± 1.5 % v. M. 1 Test voltage: 250 …1000 V adjustable in 16 steps Test current: 1 mA


Warning! Using the High Voltage Insulation Measurement

During the High Voltage Isolation Measurement it is not allowed to have a direct or indirect connection to the 230V- / 400- Mains supply!

Disconnect therefore please all loading devices from the car!

Technical data


7.2.4 Equipotential Measurement

Warning! Using the Equipotential Measurement





Equipotential Measurement

Range: Resolution: Tolerance: ± 1,5 % v. M. 1 Measuring currents 200 … 1000 mA


Technical data


7.2.5 Electrical Resistor Measurement

Warning! using the Electrical Resistor Measurement





Electrical Resistor Measurement

The measuring current depends on the measurement range and is 5mA maximum. Range Resolution Toelrances 0 Ω to 10 Ω 10 mΩ ± 1 % v. M. ± 5 mΩ2) 0 Ω to 100 Ω 0,1 Ω ± 1 % v. M. ± 50 mΩ 0 Ω to 1 kΩ 1 Ω ± 1 % v. M. ± 1 Ω 0 Ω to 10 kΩ 10 Ω ± 1 % v. M. ± 10 Ω 0 Ω to 100 kΩ 100 Ω ± 1,5 % v. M. ± 100 Ω 0 Ω to 1 MΩ 1 kΩ ± 2 % v. M. ± 1 kΩ 0 Ω to 10 MΩ 10 kΩ ± 2 % v. M. ± 10 kΩ

In case of continuity measurements at the measuring range of 10 Ω an acoustic signal sounds if the test object has a resistance of < 2 Ω.

2) The accuracy in the measurement range of 10 Ω is only valid after a zero adjustment

Technical data


7.2.6 Diode Test

Warning! using the diode test





Diode Test Measuring current: 1 mA

Measuring voltage: 5 Volt max.

The direction of the flow is indicated by a diode symbol. The reversion of polarity is done automatically during the test

Disposal:

This product by AVL DiTEST is a high-quality electrical and electronic device that must not be disposed of with household waste. For disposal, it is essential to comply with local legal obligations!

Terms


8 Terms

Table 8-1 Terms and explanations

Term Explanation

ASAM-ODX Association for Standardisation of Automation and Measuring Systems - Open Diagnostic data eXchange. ASAM ODX electronic control units are built in LT3 commercial vehicles in accordance with this standard. The diagnostic procedure and the diagnostics data may differ from those of the electronic control units in the protocols KWP1281/2000/6000, e.g. fault memory contents. ASAM ODX electronic control units work in accordance with the UDS protocol.

Firmware update Software modification package for updating existing firmware to a higher version.

Hardware Hardware primarily refers to the device itself with its mechanical structure and display and control elements, and also the basic operation.

Hybrid drive The combination of electric and internal combustion engine is referred to as the hybrid drive.

Calibration Correction of the measurement deviation of a testing device.

Equipotential Measurement

Test of the equipotential bonding (conductors and / or bus bars) between High-Voltage components and the chassis of the car.

DC voltage de-energised

Checking the DC voltage-free of electric vehicles. Vehicle must be free of tension before working!

SAE J1766 SAE: Society of Automotive Engineers. SAE J1766: SAE instruction for carrying out the insulation measurement.

USB Universal Serial Bus. USB is a standardised interface for connecting devices such as keyboards and USB storage devices.

Index


9 Index

C

Calibration .................................... 6-1 Certificate of Calibration ............... 1-2 Cleaning VAS 6558A ..................... 6-1 Components and mode of

operation .................................... 2-1

D

Designated Use ............................. 1-4 Diode Test ..................................... 5-9

E

Electrical Resistor Measurement ... 5-8 Equipotential Measurement ......... 5-10 Error messages ............................. 5-2 Exchange parts ........................... 5-12

F

Fault reports to customer service 5-11 Field of application ........................ 1-5 Firmware-update ........................... 4-1 Fischer-to-USB Adaptor ................ 2-9

G

General Information ....................... 1-1 General Notes ............................... 1-1

H

High voltage insulation measurement ............................. 5-7

I

IMPORTANT NOTICES ................. vii IMPORTANT SAFETY

INSTRUCTIONS .......................... iii Insulation measurement according to

SAE J1766 ................................. 5-6

M Maintenance and care ................... 6-1

O

Operation ....................................... 3-1

P

Power supply ................................. 2-4 Probe tips ...................................... 2-8

R

Replacement parts ...................... 5-12 Replacement parts and

accessories ............................... 5-12

S

Safety Instructions ............................. i Safety Notes .................................. 1-2 Scope of delivery ........................... 2-2 Self-test ......................................... 5-1 Switching off the VAS 6558A ......... 3-1 Switching on the VAS 6558A ......... 3-1

T

Technical data ............................... 7-1 Terms ............................................ 8-1 Test adapter .................................. 2-7 Top ................................................ 2-5 Troubleshooting ............................. 5-1

U

USB adapter with cable relief ........ 2-9

Index


V

VAS 6556/VAS 6556 Aworkshop trolley ....................... 3-2

VAS 6558 parts list ...................... 5-14 VAS 6558A function test ............... 5- 5 Voltage measurement ................... 5-5

W

Workshop trolley ............................ 2-6


We have checked the contents of the documentation to ensure they correspond to the status described. Nevertheless deviations cannot be entirely excluded and we cannot therefore guarantee complete agreement. The information in this documentation is however regularly reviewed and any corrections necessary will be incorporated in the next edition. We will be grateful to receive suggestions for improvement.

Products are subject to alterations in shape, equipment and design. For this reason, no claims may be made on the basis of the information, graphics and descriptions contained in this operating manual. Reprints, copies and translations of this document, in whole or in part, may not be undertaken without the express written consent of Volkswagen AG and/or the manufacturer with the exception that the user documentation may be supplied with each tester. Making available to third parties is not permitted. All rights provided under copyright law are expressly reserved by Volkswagen AG and the manufacturer. Subject to alteration. All rights reserved.

VOLKSWAGEN AG KD-WERKSTATTAUSRÜSTUNG D-38436 Wolfsburg Copyright Volkswagen AG 2019, AVL DiTEST 2019

Manufacturer: AVL DiTEST GmbH Alte Poststrasse 156 A-8020 Graz All rights reserved.