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Related Manuals for Volkswagen VAS 681 003A
Summary of Contents for Volkswagen VAS 681 003A
- Page 1 M o b i l e h i g h - v o l t a g e D C c h a r g e r V A S 6 8 1 0 0 3 A 41.VW.2210.3102_BA_V00_EN VAS 681 003A...
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Page 2: Legal Notice
Symbols 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. 41.VW.2210.3102_BA_V00_EN VAS 681 003A... -
Page 3: Table Of Contents
Technical data OPERATION Preparing the power supply connection Startup Initial startup Cold start Warm start Setting the contrast Startup after long downtimes Self-test Starting charging Setting the charging time Setting the auto-off function Charging the vehicle 41.VW.2210.3102_BA_V00_EN VAS 681 003A... - Page 4 Troubleshooting Warning messages Cleaning Storage Disposal Maintenance Inspection and maintenance intervals Authorized inspection and maintenance personnel Inspection and maintenance areas on the product Inspection and maintenance table Tightening torques Replacing wearing parts HELP Warranty Customer service 41.VW.2210.3102_BA_V00_EN VAS 681 003A...
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Page 5: Introduction
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 41.VW.2210.3102_BA_V00_EN VAS 681 003A... -
Page 6: Safety
This operating manual is only valid for the following product: Item number 22103102 Designation Mobile high-voltage DC charger VAS 681 003A 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! -
Page 7: Important Safety Instructions
• Ensure that the product is at least 50 cm above the ground during operation! WARNING Danger of electric shock! The electrical voltage in the product is dangerous and can cause serious injury from electric shock! • Never attempt to power other devices with the product! 41.VW.2210.3102_BA_V00_EN VAS 681 003A... -
Page 8: Safety Functions
Damage to the emergency stop button can impair the product’s safety function! • Check the function of the emergency stop button at regular intervals (see the “Pressing the emergency stop button” and “Maintenance” sections)! • Make sure that the emergency stop button is always readily accessible! 41.VW.2210.3102_BA_V00_EN VAS 681 003A... - Page 9 A signal is sent to the controller, which makes it impossible to resume charging by resetting the emergency stop button. Emergency stop pressed The message “ ” appears on the LC display. Position Description Emergency stop button LC display 41.VW.2210.3102_BA_V00_EN VAS 681 003A...
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Page 10: Intended Use
Personnel have received comprehensive training on working with electric vehicles. • Personnel have received training on working with all charging modes, in particular mode 4. • Personnel must not be under the influence of medication or drugs while using the equipment! 41.VW.2210.3102_BA_V00_EN VAS 681 003A... -
Page 11: Duties Of The Operator
The high-voltage charger is always in perfect working order. • The regular inspection intervals for the high-voltage charger are observed and recorded. • Replacement of components is logged when the maximum number of mating cycles is reached. 41.VW.2210.3102_BA_V00_EN VAS 681 003A... -
Page 12: Transport And Storage
• Always use a suitable industrial truck or hoist to transport the packaged product! CAUTION Risk of damage! Slings suspended from indoor cranes can damage the packaging! • Do not transport the packaged product using slings and indoor cranes. 41.VW.2210.3102_BA_V00_EN VAS 681 003A... -
Page 13: Unpacking The Product
• When cutting the packaging straps, take care not to cut through the cardboard! • Carefully remove the protective foil from the cables! Carefully cut the packaging straps. Remove the top half of the heavy duty cardboard box. 41.VW.2210.3102_BA_V00_EN VAS 681 003A... - Page 14 When in the vertical position, the product’s own weight engages the parking brakes. Remove the protective foil from the wiring harnesses. The product is now unpacked. You can now check the scope of delivery (see the “Scope of delivery” section). 41.VW.2210.3102_BA_V00_EN VAS 681 003A...
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Page 15: Transporting The Product At The Place Of Use
The parking brake on the wheels automatically engages as soon as the product is upright. When the product is set down on its front feet, the product’s own weight causes the brake to be pressed against the wheels. (1) Parking brake (2) Wheel (3) Front feet 41.VW.2210.3102_BA_V00_EN VAS 681 003A... -
Page 16: Adjusting The Parking Brake
Turn the set screw to adjust the pressure on the wheel so that it fixes it securely in place. Tighten the upper lock nut. Check the adjustment and repeat if necessary. The parking brake is now adjusted. 41.VW.2210.3102_BA_V00_EN VAS 681 003A... -
Page 17: Ambient Conditions At The Place Of Use
• Never operate the product on carpet or other textile floor coverings! • Observe the permitted ambient temperatures (see the “Technical data” section)! To ensure optimum ventilation, always maintain at least one meter of clearance from other bodies and the wall. 41.VW.2210.3102_BA_V00_EN VAS 681 003A... -
Page 18: Product Description
Scope of delivery Immediately check the condition of the product and the completeness of the delivery. If anything is missing or defective, please contact the manufacturer immediately. (1) High-voltage DC charger (2) USB stick with operating manual 41.VW.2210.3102_BA_V00_EN VAS 681 003A... -
Page 19: Design
EN | Product description Design Product design: (1) Emergency stop button (2) Service port (3) LC display with membrane keypad (4) CCS charging plug (5) Power supply plug (6) Handle (7) Rubber cushion (8) Wheels 41.VW.2210.3102_BA_V00_EN VAS 681 003A... -
Page 20: Symbols And Connections
Nameplate The nameplate contains information about the manufacturer, the product type, the year of manufacture and the serial number. You can use the serial number to track information relating to production. 41.VW.2210.3102_BA_V00_EN VAS 681 003A... - Page 21 The test seal identifies the product as having been approved for use in workshops and production facilities belonging to the vehicle manufacturer. QR code for accessing the operating manual on mobile devices. 41.VW.2210.3102_BA_V00_EN VAS 681 003A...
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Page 22: Displays And Controls
“Safety” section. LC display with • Displays the operating status membrane keypad • Controls charging functions The individual functions of the LC display and the method for operating the membrane keypad are described in the “Operation” section. 41.VW.2210.3102_BA_V00_EN VAS 681 003A... -
Page 23: Technical Data
Elevation above sea level Max. 2000 m No limitation. Humidity Max. 80% up to 31° C, decreasing linearly to 50% at 40° C. Condensation not permitted. Maximum permissible relative humidity: 60 % in environments with corrosive gas/air. 41.VW.2210.3102_BA_V00_EN VAS 681 003A... -
Page 24: Operation
• Connect the product only to grounded electrical installations with protective and neutral conductors! • Do not use extension cables and use only adapters approved by the manufacturer to connect the product to the power supply! 41.VW.2210.3102_BA_V00_EN VAS 681 003A... -
Page 25: Startup
Position the vehicle next to the power supply! • Ensure that persons do not enter the area where the product is being used without due care! • Take special care when entering the area where the product is being used! 41.VW.2210.3102_BA_V00_EN VAS 681 003A... -
Page 26: Initial Startup
This section explains the actions required to carry out a cold start of the product. To carry out a cold start, perform the steps for initial startup, with the exception of steps 3 and 4. 41.VW.2210.3102_BA_V00_EN VAS 681 003A... -
Page 27: Warm Start
” submenu by pressing function key F1. Contrast Navigate to the “ ” parameter by pressing function keys F2 (down) and F3 (up). Contrast Select the “ ” parameter to edit by pressing function key F4 (select). 41.VW.2210.3102_BA_V00_EN VAS 681 003A... -
Page 28: Startup After Long Downtimes
The high-voltage DC charger runs a self-test as soon as you start it up. The message “ check ” and a progress bar appear on the LC display. During the self-test, the product tests all electrical systems required for safety and proper functioning. The self-test takes about 50 seconds. 41.VW.2210.3102_BA_V00_EN VAS 681 003A... -
Page 29: Starting Charging
0:01 and 24:00 (hh:mm format). Confirm the set value by pressing function key F4 (confirm). Exit the parameter menu by pressing function key F1 (exit). You have successfully set the charging time for the DC charger. 41.VW.2210.3102_BA_V00_EN VAS 681 003A... -
Page 30: Setting The Auto-Off Function
0:01 and 24:00 (hh:mm format). Confirm the set value by pressing function key F4 (confirm). Exit the parameter menu by pressing function key F1 (exit). You have set the auto-off function of the DC charger. 41.VW.2210.3102_BA_V00_EN VAS 681 003A... -
Page 31: Charging The Vehicle
If necessary, start the charging process on the vehicle as described in the operating manual from the vehicle manufacturer. The charging process starts automatically once the high-voltage DC charger has established communication with the battery management system. 41.VW.2210.3102_BA_V00_EN VAS 681 003A... -
Page 32: Finishing Charging
Canceling the charging process WARNING Danger of fatal electric shock! Product components may produce sparks and electric arcs! • Never disconnect high-voltage plug connections while under load! • Finish the charging process before disconnecting the plug connections! 41.VW.2210.3102_BA_V00_EN VAS 681 003A... - Page 33 The DC high-voltage charger cancels the charging process and switches off. Press and hold the unlock button. Remove the CCS charging plug from the charging socket on your vehicle. Charging has now been canceled. 41.VW.2210.3102_BA_V00_EN VAS 681 003A...
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Page 34: Using The Lc Display
Display the operating parameters. Down: Scroll down through the selection options. Scroll up through the selection options. Wrench: Display the configuration parameters. Info: Display the information parameters. Select: Select the highlighted menu item. Confirm: Confirm the set parameter. 41.VW.2210.3102_BA_V00_EN VAS 681 003A... -
Page 35: Menu Structure
Menu structure The figure below shows the menu structure and how you can navigate within it. The individual parameters are described in the tables below. The “Configuration parameters” menu is not available while charging is active. 41.VW.2210.3102_BA_V00_EN VAS 681 003A... -
Page 36: Main Menu
Current output power of the high-voltage DC charger Counter Amount of energy delivered during the charging process Electrical charge delivered during the charging process Protocol Displays the charging communication protocol used The following messages may be displayed: 41.VW.2210.3102_BA_V00_EN VAS 681 003A... - Page 37 Indicates the power reduction due to Derating temperature limits. Insulation 1 Resistance values between DC+, PE and DC- kΩ/MΩ Z+/Z- Insulation 2 Resistance values as a function of the actual kΩ/V Z+/Z- voltage INS OK Insulation monitoring status 41.VW.2210.3102_BA_V00_EN VAS 681 003A...
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Page 38: Configuration Parameters
Time after which the high-voltage DC charger switches off automatically after charging is finished Language Menu language German Contrast Contrast of the LC display Temp. Unit Unit in which temperatures are °C Degrees Celsius shown on the LC display 41.VW.2210.3102_BA_V00_EN VAS 681 003A... -
Page 39: Information Parameters
Number of closing cycles for the DC relay Temp. AC Max Maximum temperature at the AC measuring point °C Temp. DC Max Maximum temperature at the DC measuring point °C Temp. CCS Max Maximum temperature at the charging plug °C 41.VW.2210.3102_BA_V00_EN VAS 681 003A... - Page 40 Number of overtemperature violations at the AC input Temp.fault DC Number of overtemperature violations at the DC output Temp.fault CCS Number of overtemperature violations at the CCS plug Tmp. Fault Number of overtemperature violations at the AC/DC AC/DC converter 41.VW.2210.3102_BA_V00_EN VAS 681 003A...
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Page 41: Restoring The Factory Settings
” and a progress bar appear. Press and hold function keys F1 to F4 until the progress bar reaches 100%. You have successfully loaded the factory settings. The language of the LC display has been changed to English. 41.VW.2210.3102_BA_V00_EN VAS 681 003A... -
Page 42: Troubleshooting
Contact the manufacturer before reaching the maximum number of mating cycles! An insulation fault By the operator or a high voltage specialist: was detected in the • Inspect the vehicle. connection to the • Perform vehicle diagnostics. vehicle. 41.VW.2210.3102_BA_V00_EN VAS 681 003A... - Page 43 The permissible By the operator: temperature was • Check the number of mating cycles exceeded at the CCS for the CCS charging plug. Replace charging plug. the CCS charging plug if necessary. • Contact the manufacturer. 41.VW.2210.3102_BA_V00_EN VAS 681 003A...
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Page 44: Cleaning
The electrical voltage in high-voltage systems is lethal and will 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. 41.VW.2210.3102_BA_V00_EN VAS 681 003A... -
Page 45: Storage
This section provides information about the following: • Inspection and maintenance intervals • Authorized inspection and maintenance personnel • Inspection and maintenance areas on the product • The inspection and maintenance table 41.VW.2210.3102_BA_V00_EN VAS 681 003A... -
Page 46: Inspection And Maintenance Intervals
High voltage Personnel with this qualification level have the professional training necessary to recognize and avoid hazards that can arise from high-voltage systems. CAR-connect Activities marked with this abbreviation may only be carried out by the manufacturer. 41.VW.2210.3102_BA_V00_EN VAS 681 003A... -
Page 47: Inspection And Maintenance Areas On The Product
Inspect the plastic casing and the handles for damage. Inspecting the housing screws Inspect all screws on the housing, the handle and the wheels to make sure they are tight and none are missing. Tighten the screws if necessary. 41.VW.2210.3102_BA_V00_EN VAS 681 003A... - Page 48 Replacing the AC plug The AC plug must be replaced if worn. Replacing the CCS charging plug The CCS charging plug must be replaced if it is worn or has reached the maximum number of mating cycles. 41.VW.2210.3102_BA_V00_EN VAS 681 003A...
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Page 49: Tightening Torques
(see the “Replacing wearing parts” section). Tightening torques The following table shows the maximum permissible torques for all screw connections. Observe the maximum torques when fastening components. Screw size Torque 2 Nm 3.5 Nm 6 Nm 16 Nm 41.VW.2210.3102_BA_V00_EN VAS 681 003A... -
Page 50: Replacing Wearing Parts
(see the “Tightening torques” section). CAUTION Risk of damage! Products can be damaged if they fall. • Always place the product on a workbench before performing maintenance work. • Secure the product so that it cannot slip! 41.VW.2210.3102_BA_V00_EN VAS 681 003A... - Page 51 Coil the cables and place them next to the product. Make sure that the cables do not fall. The product is now ready for you to replace wearing parts. 41.VW.2210.3102_BA_V00_EN VAS 681 003A...
- Page 52 Replacing the lower filter mat Remove the screws from the bottom cover. Remove the bottom cover. Replace the filter mat. Reattach the top cover using the screws. You have successfully replaced the lower filter mat. 41.VW.2210.3102_BA_V00_EN VAS 681 003A...
- Page 53 Remove the screw. Remove the old wheel. Replace the wheel. Fasten the new wheel with the screw. Adjust the parking brake if necessary (see the “Adjusting the parking brake” section). You have successfully replaced the wheels. 41.VW.2210.3102_BA_V00_EN VAS 681 003A...
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Page 54: Help
Always include the serial number with any product queries. This number 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 service@car-connect.cc www.car-connect.cc 41.VW.2210.3102_BA_V00_EN VAS 681 003A... - Page 55 Volkswagen Aktiengesellschaft K-GVO-LW Group After Sales – Group Service Literature and Systems Repair Shop Equipment PO box 011/4915 38442 Wolfsburg, Germany For internal use only Subject to technical changes Edition 03 / 2021 41.VW.2210.3102_BA_V00_EN VAS 681 003A...
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