Battery, Charging

Battery, Charging

CAUTION!
Risk of injury. Observe warning notes and safety precautions. Refer to => [ Warnings and Safety Precautions ] Battery A!

CAUTION!
In order to prevent damage to the Battery (A) or vehicle, observe battery type descriptions and notes. Refer to => [ Battery Types ] Battery Types.

=> [ Battery Charger VAS 5095 A ]

=> [ Battery Charger VAS 5900 ]

=> [ Severely Discharged Batteries ]

Battery Charger VAS 5095 A

In this chapter, the base functions of the (VAS 5095 A) are described. Refer to (VAS 5095 A) Operating Instructions for more information.

• Refer to the (VAS 5095 A) Operating Instructions.

• Observe the handling instructions of the battery manufacturer!

Battery Charger Description

The (VAS 5095 A) is intended for charging

• Wet batteries (original VW-batteries, as of 2004 transparent battery housing with black cover)

• Valve-regulated lead acid batteries (original VW-batteries, as of 2004 complete battery housing black)

The battery is charged without amperage or voltage surges. Thereby the on-board electronics will not be affected. It is not necessary to remove Battery (A) from the vehicle or be disconnected from the electrical system during charging.

(VAS 5095 A)

1. Switch ON/OFF (0 = Charger OFF)

2. Charge current display (I greater than 12 A)

3. Charge current display Battery (A) partially charged (greater than 90 %)

4. Maintenance charging, lights up green when the Battery (A) is charged

5. Interference indicator

6. Support mode indicator

7. Support mode/normal mode selector switch

8. Charger cables, red charging clamp "+", black charging clamp "-".

9. Battery type selector switch (base of loading devices)

Battery, Charging

CAUTION!
Risk of injury. Observe warning notes and safety precautions. Refer to => [ Warnings and Safety Precautions ] Battery A!

Special tools, testers and auxiliary items required

• Battery Charger VAS 5903 (VAS 5095 A)

CAUTION!
While charging, always set the battery type to 2.4 V/C (Volts/Cell)! This applies to all Battery (A).

• Battery temperature must be at least +10 ?.

• On Battery (A) with cell caps, the caps must not be opened when charging the Battery (A).

CAUTION!
• Turn off the ignition and all electrical components.

• Remove the ignition key.

Procedure

- Check the battery type setting on the battery type selector. It must be set to 2.4V/C (Volts/Cell).

- Connect the (VAS 5095 A) red charging clamp " +" to the Battery (A) positive terminal.

- Connect the (VAS 5095 A) black charging clamp " -" to the Battery (A) negative terminal.

- Switch the (VAS 5095 A) on.

The charge current display (refer to ) - 2 - and - 3 - light up yellow. The Battery (A) is partially charged (approximately 90%) only when the yellow LED - 3 - is on.

If the green LED (refer to ) - 4 - is also on, then the (VAS 5095 A) has switched to maintenance charging. The Battery (A) is charged.

- Switch the (VAS 5095 A) off.

- Remove the charger clamps from the battery terminals.

Severely Discharged Battery, Charging

CAUTION!
Risk of injury. Observe warning notes and safety precautions. Refer to => [ Warnings and Safety Precautions ] Battery A!

The (VAS 5095 A) automatically detects severely discharged Battery (A) and starts the charging process conservatively with a low charging current. The charge current is automatically adjusted to the battery charge state.

• Observe the notes in chapter. Refer to => [ Severely Discharged Batteries ].

• Batteries which have not been used for lengthy periods, for example, in vehicles which have not been driven, are subject to self-discharge.

• A Battery (A) is considered to be severely discharged if open-circuit voltage drops below 11.6 V. The Battery (A) is pre-damaged when the voltage is between 12.2 V and 11.6 V. Measuring open-circuit voltage => [ Battery Resting Voltage, Checking ] Testing and Inspection.

• The electrolyte (mixture of sulfuric acid and water) is mostly water, with a greatly reduced sulfuric acid content in severely discharged Battery (A).

• Severely discharged Battery (A) become sulfated, meaning all of the plate surfaces harden. Instead of being transparent, the electrolyte has a slightly milky appearance.

• The sulfation process may be reversed if a severely discharged Battery (A) is recharged immediately.

• If the Battery (A) is not recharged, the plates will continue to harden, and the ability to accept a charge will decrease. This results in reduction of battery performance.

Severely discharged sulfated Battery (A) must be charged as follows using a low charging current:

- Adjust the charge current to approximately 5% of the battery capacity (for a 60 Ah-Battery (A) the charging current is approximately 3 A).

- Charge the Battery (A).

• The charging voltage may be a maximum of 14.4 V.

(VAS 5095 A) Support Mode

CAUTION!
Risk of injury. Observe warning notes and safety precautions. Refer to => [ Warnings and Safety Precautions ] Battery A!

Using support mode, the (VAS 5095 A) stands in for the defective Battery (A) in the vehicle while it is being replaced. The on-board voltage is maintained. It is possible to use the electrical equipment.

Special tools, testers and auxiliary items required

• Battery Charger VAS 5903 (VAS 5095 A)

CAUTION!
• Using support mode, always set the battery type to 2.4 V/C (Volts/Cell)! This applies to all Battery (A).

• The charging clamps of the (VAS 5095 A) may not be disconnected from the battery terminal clamps while replacing the battery.

CAUTION!
• Turn off the ignition and all electrical components.

• Remove the ignition key.

- Set the support mode/normal mode selector to "support mode ".

- Clamp the red charging clamp "+" on the (VAS 5095 A) to the vehicle positive battery terminal.

- Clamp the black charging clamp "+" on the ( VAS 5095 A) to the vehicle negative battery terminal.

- Check the battery type setting on the battery type selector. It must be set to 2.4 V/Z.

- Switch the (VAS 5095 A) on.

The yellow LEDs light up.

• A minimum load of 0.6 A, for example, parking lamps, must be switched on, otherwise support mode is not possible.

• During the support mode, the current is limited to 5 A.

- Switch on the vehicle parking lamps.

- Replace the Battery (A). Refer to => [ Battery A ] Removal and Replacement.

- Switch the (VAS 5095 A) off.

- Remove the charger clamps from the battery terminals.

- Set the support mode/normal mode selector to "normal mode ".

Buffer Mode and Maintenance Charging

CAUTION!
Risk of injury. Observe warning notes and safety precautions. Refer to => [ Warnings and Safety Precautions ] Battery A!

In buffer mode, the (VAS 5095 A) provides safe charging and maintenance charging of the battery.

- Proceed as when charging the Battery (A).

• If the Battery (A) is loaded by an electrical consumer during the buffer mode, the (VAS 5095 A) automatically provides sufficient charge.

• The buffer mode can be operated for an unlimited period of time.

• The Battery (A) can be used constantly.

• Observe the maintenance notes of the battery manufacturer.

Battery Charger VAS 5900

CAUTION!
Risk of injury. Observe warning notes and safety precautions. Refer to => [ Warnings and Safety Precautions ] Battery A!

In this chapter, the base functions of the (VAS 5900) are described. Refer to the (VAS 5900) Operating Instructions.

• Refer to the Operating Instructions that came with the (VAS 5900).

• Observe the handling instructions of the battery manufacturer!

Battery Charger Description

The (VAS 5900) is intended for charging

• Wet batteries (original VW-batteries, as of 2004 transparent battery housing with black cover)

• Valve-regulated lead acid batteries (original VW-batteries, as of 2004 complete battery housing black)

Battery Charger (VAS 5900)

1. Display

2. Adjustment button "Up" [Up Arrow]

3. Adjustment button "Down" [Down Arrow]

4. START/STOP

5. INFO

Battery, Charging

CAUTION!
Risk of injury. Observe warning notes and safety precautions. Refer to => [ Warnings and Safety Precautions ] Battery A!

Special tools, testers and auxiliary items required

• Battery Charger VAS 5903 (VAS 5900)

• The temperature of the Battery (A) must be at least +10° C.

• On Battery (A) with cell caps, the caps must not be opened when charging the Battery (A).

CAUTION!
• Turn off the ignition and all electrical components.

• Remove the ignition key.

Procedure

- Insert the (VAS 5900) network connector. The last selected operation mode is shown on the display.

- Using the INFO button, set the mode of operation that corresponds with the Battery (A).

The symbol - 1 - for "standard charge of wet batteries" or the symbol - 2 - for "standard charge of Gel/Absorbent Glass Mat (AGM) batteries" is indicated in the display.

- Adjust the battery capacity (Ah) on the Battery ( A) to be charged with the corresponding "Up" [Up Arrow] or "Down" [Down Arrow] button.

- Clamp the red charging clamp "+" to the positive Battery (A) terminal.

- Clamp the black charging clamp "-" to the negative Battery (A) terminal.

The (VAS 5900) recognizes the nominal voltage of the connected Battery (A) (6 V, 12V, or 24 V) and begins the charging process automatically.

The (VAS 5900) begins the "final charging " when the charge is approximately 80 - 85 %. The fourth bar is indicated on the display - 1 -. The Battery (A) is ready for operation.

With a charge status of 100 %, all bars are indicated on the display.

• With the battery type "standard charge", parallel operation of components during the charging process is possible. The charging time is lengthened by this.

• The (VAS 5900) switches to maintenance charging after approximately 1 to 7 hours, depending on the type of battery. To reach a 100% charge condition, the Battery (A) should remain connected to the (VAS 5900).

Possible malfunctions and how they are handled:

1 - Displayed voltage does not match the nominal voltage:

- Hold the appropriate button "Up" [Up Arrow] or " Down" [Down Arrow] until the charging process begins.

2 - Displayed battery voltage does not match rated voltage - charging process has already begun:

- Press START/STOP twice.

- Hold the appropriate button "Up" [Up Arrow] or " Down" [Down Arrow] until the charging process begins again.

3 - The (VAS 5900) does not detect the Battery (A) if the battery voltage is less than 2 V.

The display remains unchanged.

The selected battery type and Ampere hours (Ah) are displayed.

End the Battery (A) charging process:

- Press START/STOP.

- Disconnect the black charging clamp "-" on the (VAS 5900) from the Battery (A) negative terminal.

- Disconnect the red charging clamp "+" on the ( VAS 5900) from the Battery (A) positive terminal.

- Disconnect the (VAS 5900) network connector.

Service Charging with (VAS 5900)

CAUTION!
Risk of injury. Observe warning notes and safety precautions. Refer to => [ Warnings and Safety Precautions ] Battery A!

CAUTION!
"Service charging" is not permitted for VW vehicles, because voltage surges can damage the on-board electronics.

If "Service charging" is still used, the Battery (A) must always be disconnected from the vehicle electrical system.

CAUTION!
Always set the operating mode that corresponds to the Battery (A). Refer to the Operating Instructions (VAS 5900).

The "service charging" may only be used for:

• Wet batteries, that can be topped up with distilled water.

• Gel/AGM batteries.

Do not use the operation mode "service charging" for maintenance-free wet batteries => [ Battery Types ] Battery Types.

The "service charging (SERV)" operating mode is only used for Battery (A) that are possibly faulty (e.g. sulfation). The Battery (A) is then charged to the maximum specific gravity of the electrolyte and the plates are reactivated (removal of sulfation layer).

Special tools, testers and auxiliary items required

• Battery Charger VAS 5903 (VAS 5900)

• The temperature of the Battery (A) must be at least +10° C.

• On Battery (A) with cell caps, the caps must not be opened when charging the Battery (A).

CAUTION!
• Turn off the ignition and all electrical components.

• Remove the ignition key.

Procedure

- Insert the (VAS 5900) network connector. The last selected operation mode is shown on the display.

- Using the INFO button, set the mode of operation that corresponds with the Battery (A).

• The "service charging" process depends on the degree of sulfation on the Battery (A).

Possible malfunctions and how they are handled:

1 - Displayed voltage does not match the nominal voltage:

- Hold the appropriate button "Up" [Up Arrow] or " Down" [Down Arrow] until the charging process begins.

2 - Displayed battery voltage does not match rated voltage - charging process has already begun:

- Press START/STOP twice.

- Hold the appropriate button "Up" [Up Arrow] or " Down" [Down Arrow] until the charging process begins.

3 - The (VAS 5900) does not detect the Battery (A) if the battery voltage is less than 2 V.

The display remains unchanged.

The set operating mode and Ampere-hours (Ah) are displayed.

End the Battery (A) charging process:

- Press START/STOP.

- Disconnect the black charging clamp "-" on the (VAS 5900) from the Battery (A) negative terminal.

- Disconnect the red charging clamp "+" on the ( VAS 5900) from the Battery (A) positive terminal.

- Disconnect the (VAS 5900) network connector.

Severely Discharged Battery, Charging

CAUTION!
Risk of injury. Observe warning notes and safety precautions. Refer to => [ Warnings and Safety Precautions ] Battery A!

CAUTION!
• The polarity protection of the charger clamps is not active in the operation mode "charging severely batteries/Support mode". Connect the charger clamps to the battery terminals correctly according to polarity!

• Always set the operating mode that corresponds to the Battery (A). Refer to the Operating Instructions (VAS 5900).

• The (VAS 5900) does not detect a severely discharged Battery (A). Refer to => [ Severely Discharged Batteries ].

• Do not touch START/STOP if the charge clamps are connected incorrectly! The (VAS 5900) can be damaged.

If the Battery (A) has charge less than 2 volts, then the (VAS 5900) is not able to automatically detect the Battery (A).

Special tools, testers and auxiliary items required

• Battery Charger VAS 5903 (VAS 5900)

• The temperature of the Battery (A) must be at least +10° C.

• On Batteries (A) with cell caps, the caps must not be opened when charging the Battery (A).

CAUTION!
• Turn off the ignition and all electrical components.

• Remove the ignition key.

Procedure

- Insert the (VAS 5900) network connector. The last selected operation mode is shown on the display.

- Using the INFO button, set the mode of operation that corresponds with the Battery (A).

The symbol - 1 - for "service charging of wet batteries" or the symbol - 2 - for "service charging of Gel/Absorbent Glass Mat (AGM) batteries" is indicated in the display.

- Adjust the battery capacity (Ah) on the Battery ( A) to be charged with the corresponding "Up" [Up Arrow] or "Down" [Down Arrow] button.

- Clamp the red charging clamp "+" to the positive Battery (A) terminal.

- Clamp the black charging clamp "-" to the negative Battery (A) terminal.

- Press the START/STOP button for approximately 5 seconds. The menu selection "Charging severely discharged batteries/Support mode " is activated.

- Press corresponding button "Up" [Up Arrow] or " Down" [Down Arrow], to set respective battery voltage (6 V, 12 V or 24 V).

• If no button is touched within 5 seconds, the Battery Charger (VAS 5900) will return to the main menu (operating mode selection).

- Confirm the selected battery voltage by pressing START/STOP.

Then the inquiry about the correct polarity of the charger clamps is made.

- Verify that the charger clamps are connected to the correct polarity.

- Confirm that the charger clamps are connected to the correct polarity by pressing START/STOP.

The (VAS 5900) begins charging the severely discharged Battery (A).

End the Battery (A) charging process:

- Press START/STOP.

- Disconnect the black charging clamp "-" on the (VAS 5900) from the Battery (A) negative terminal.

- Disconnect the red charging clamp "+" on the ( VAS 5900) from the Battery (A) positive terminal.

- Disconnect the (VAS 5900) network connector.

(VAS 5900) Support Mode

CAUTION!
Risk of injury. Observe warning notes and safety precautions. Refer to => [ Warnings and Safety Precautions ] Battery A!

CAUTION!
• The polarity protection of the charger clamps is not active in the operation mode "charging severely batteries/Support mode". Connect the charger clamps to the battery terminals correctly according to polarity!

• Always set the operating mode that corresponds to the Battery (A). Refer to the Operating Instructions (VAS 5900).

• Do not touch START/STOP if the charge clamps are connected incorrectly! The charger can be damaged.

Using support mode, the (VAS 5900) stands in for the defective Battery (A) in the vehicle while it is being replaced. The on-board voltage is maintained. It is possible to use the electrical equipment.

Special tools, testers and auxiliary items required

• Battery Charger VAS 5903 (VAS 5900)

CAUTION!
• Turn off the ignition and all electrical components.

• Remove the ignition key.

Procedure

- Insert the (VAS 5900) network connector. The last selected operation mode is shown on the display.

- Press the START/STOP button for approximately 5 seconds. The menu selection "Charging severely discharged batteries/Support mode " is activated.

- Press corresponding button "Up" [Up Arrow] or " Down" [Down Arrow], to set respective vehicle electrical system voltage (6 V, 12 V or 24 V).

• If no button is touched within 5 seconds, the (VAS 5900) will return to the main menu (operating mode selection).

- Confirm the selected battery voltage by pressing START/STOP.

- Clamp the red charging clamp "+" on the (VAS 5900) to the vehicle positive battery terminal.

- Clamp the black charging clamp "+" on the ( VAS 5900) to the vehicle negative battery terminal.

Then the inquiry about the correct polarity of the charger clamps is made.

- Verify that the charger clamps are connected to the correct polarity.

- Confirm that the charger clamps are connected to the correct polarity by pressing START/STOP.

The (VAS 5900) starts the assistance mode.

- Replace the Battery (A). Refer to => [ Battery A ] Removal and Replacement.

- Press START/STOP. The support mode is ended.

- Remove the black charging clamp "-" on the ( VAS 5900) from the vehicle negative battery terminal.

- Remove the red charging clamp "+" on the ( VAS 5900) from the vehicle positive battery terminal.

- Disconnect the (VAS 5900) network connector.

Sustain Charge with (VAS 5900)

CAUTION!
Risk of injury. Observe warning notes and safety precautions, refer to => [ Warnings and Safety Precautions ] Battery A!

If the Battery (A) is fully charged, the (VAS 5900) begins to sustain the charge.

- Proceed as when charging the Battery (A).

With a charge status of 100%, all bars are indicated on the display.

• If Battery (A) is discharged by a consumer during sustain charging, the (VAS 5900) automatically supplies the corresponding charge.

• Charge retention can be performed without time restrictions.

• The Battery (A) can be used constantly.

• Observe the maintenance notes of the battery manufacturer.

Severely Discharged Batteries

CAUTION!
Risk of injury. Observe warning notes and safety precautions, refer to => [ Warnings and Safety Precautions ] Battery A!

For a Battery (A) to be designated as " severely discharged", the resting voltage must be less than 12.2 V.

CAUTION!
• Severely discharged Battery (A) freeze earlier.

• Battery (A) that have frozen must no longer be used.

• Battery (A), which have not been used for lengthy periods, for example, in vehicles which have not been driven, are subject to self-discharge.

• In severely discharged Battery (A), the electrolyte consists almost completely of water, because the acid portion has been greatly reduced.

• Severely discharged Battery (A) become sulfated, meaning all of the plate surfaces harden.

• The sulfation process may be reversed if a severely discharged Battery (A) is recharged immediately.

• If the Battery (A) is not recharged, the plates will continue to harden, and the ability to accept a charge will decrease. This results in reduction of battery performance.

Procedure

- Check Battery (A) no load voltage. Refer to => [ Battery, Charging ] Battery, Charging.

- Charge the Battery (A). Refer to => [ Battery, Charging ] Battery, Charging.

Charge the Battery (A) with the ( VAS 5095 A). Refer to => [ Battery Charger VAS 5095 A ].

Charge the Battery (A) with the ( VAS 5900). Refer to => [ Battery Charger VAS 5900 ].