Volkswagen VAS 581 009 Quick Start Manual

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VAS 581 009

Unpacking instructions Placing into service instructions Quick start guide

V2.00 05/18

Please read carefully!

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Contents

SAFETY INSTRUCTIONS ............................................................................... 2

SAFETY INSTRUCTIONS FOR CARBON DIOXIDE CO2 (R744) .................. 4

SAFETY INSTRUCTIONS FOR NITROGEN N2 .............................................. 5

OTHER SAFETY INSTRUCTIONS ................................................................. 5

OPERATING AND AUXILIARY MATERIALS ................................................. 5

1 IMPORTANT INFORMATION .................................................................. 6

2 UNPACKING INSTRUCTIONS ................................................................ 7

3 SCOPE OF DELIVERY ............................................................................ 9

4 PLACING INTO SERVICE ..................................................................... 10

4.1 Installation location / stability .................................................................................... 10

4.2 Checking the vacuum pump oil ................................................................................. 11

4.3 Power connection ..................................................................................................... 11

4.4 Switching on the VAS 581 009 ................................................................................. 12

4.5 Pressure zeroing ....................................................................................................... 17

4.6 Oil/UV additive scales zeroing .................................................................................. 18

4.7 Connecting the refrigerating agent cylinder CO2 (R744) .......................................... 19

5 AVAILABLE ACCESSORIES ................................................................ 31

6 QUICK START GUIDE ........................................................................... 32

7 FAULT CONDITIONS ............................................................................ 34

We reserve the right to make changes to the form, equipment and technology of the delivery. Therefore, no rights can be derived from the specifications, figures and descriptions in these instructions. Reprinting, reproduction or translation for third parties, in part or in whole, are not permitted without the written permission of Volkswagen AG/the manufacturer. Volkswagen AG / the manufacturer expressly reserves all rights under the German Copyright Act. Subject change.

VOLKSWAGEN AG Publisher: AVL DiTEST GmbH KD-Werkstattausrüstung Alte Poststraße 156 D-38436 Wolfsburg 8020 Graz AUSTRIA VAS 581 009 AVL DiTEST ID No. AT7912EN Rev. 02 ASE 581 009 00 000

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Safety instructions

SAFETY INSTRUCTIONS

Sign and symbols

Symbols with the following meanings are used in the safety instructions of the operating instructions, unpacking instructions, placing into service instructions, quick start guide or other supplied instructions as well as on the display of the tester during operation and on the products themselves:

DANGER

Indicates an extreme danger that can lead to death if not avoided.

WARNING

Indicates an imminent danger that can lead to death or severe injury if not avoided.

CAUTION

Indicates a danger that can lead to moderate or minor injuries.

Prohibition signs

Fire and open

flames

prohibited

Warning signs

General

Risk of electric

shock

Hazardous

gases

Warning of gas

cylinders

Danger of

suffocation

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Safety instructions

Mandatory signs

Wear

protective

goggles

Wear gloves

Refrigeratin

g agent

cylinder

Secure CO2

(R744)

Wear

protective

shoes

Wear

respiratory

protection

Wear

protective

clothing

Other symbols

Observe

operating

instructions

Fuse

First aid

Gas cylinder

Notices

NOTICE

This text points to situations or mal operations that can lead to damage or data loss.

Information

This text indicates important information or instructions. Failure to comply with these instructions will prevent or significantly hinder the successful implementation of the actions described in this documentation.

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Safety instructions

SAFETY INSTRUCTIONS FOR CARBON DIOXIDE CO

(R744)

Always observe the manufacturer's safety data sheet!

WARNING

Contact with the product can cause cold burns or frostbite. Gases/vapours are heavier than air. High concentration due to accumulation in closed rooms, work pits, cellars, etc. can cause asphyxiation, among other things. Symptoms: Loss of motor ability and consciousness. Affected persons do not realise that they are suffocating. Do not allow carbon monoxide to enter sewage systems, pits or similar enclosures where gas accumulation may be dangerous.

Precautions and behaviour rules

WARNING

Storage: Store container in a well-ventilated place at a temperature below 50 °C. Protect container against impacts and falls (secure with chain).

Handling: Avoid contact with eyes and skin. Do not inhale the gas. Ensure that no water

enters the gas cylinder/container. Prevent the gas from flowing back into the gas tank. Only use equipment that is suitable for this product and the intended pressure and temperature. Check fittings, connections and lines for leaks. Eating, drinking and storing food in the working area are prohibited.

Respiratory protection: Self-contained breathing apparatus. Eye protection: Tightly fitting protective goggles. Hand protection: Protective gloves (material: leather). Body protection: Protective clothing.

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Safety instructions

Behaviour in the event of danger

After a gas leak: Keep unprotected persons away. Ventilate rooms well. Wear protective gear and self-contained breathing apparatus. Close valves / stop gas leak. Avoid entry into cellars, pits and similar enclosures (danger of suffocation).

In case of fire: Wear protective gear and self-contained breathing apparatus. Stop gas leak if possible. Cool cylinders with a water jet from a secure position and remove them from the fire zone if possible to prevent explosion! The product itself is non-flammable.

Extinguishing agents: All known extinguishing agents can be used. Escape routes: Escape routes must be known to staff. Accident phone: The accident phone must be known to staff.

First aid

Please observe the instructions for use and safety of your refrigerant supplier..

SAFETY INSTRUCTIONS FOR NITROGEN N

Always observe the manufacturer's safety data sheet!

For safety instructions, please refer to the operating instructions.

OTHER SAFETY INSTRUCTIONS

For safety instructions, please refer to the operating instructions.

OPERATING AND AUXILIARY MATERIALS

Before using operating and auxiliary materials, the material safety data sheets for the product and the manufacturer's instructions must be read.

An appropriate safety concept must be developed and adhered to based on these material safety data sheets.

KEEP THESE INSTRUCTIONS IN A SAFE PLACE!

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Important information

1 Important information

Dear Customer, Please observe the following points in case of transport damage/incomplete delivery.

External damage to goods/packaging (without/with outer packaging):

 Describe the damage (condition of the goods/packaging)  Include photos whenever possible (before and after unloading)  Write down the damage on the freight documents and have the driver sign.  Contact Volkswagen, K-VO-W department as soon as possible.

No external damage to goods/packaging / subsequently discovered defects / missing parts:

 Describe the damage  Include photos if possible  Check the delivery; see unpacking instructions, placing into service instructions,

Sec. 2 "Scope of delivery"

 Please contact

AVL DiTEST Fax +49 9103 7131-112 immediately

Warranty

The warranty period is 12 months starting from the day of registration / activation of the device. Please use the information provided on the device to register/activate and place the device into service.

For further information, please contact:

AVL DiTEST Deutschland

Tel.: +49 9103 7131-200 Fax: +49 9131 7131-112 e-mail: [email protected]

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Unpacking instructions

2 Unpacking instructions

Required tools:

- Scissors/side cutter

- Size-14 spanner

- Size-25 spanner

Fig. 2-1 Packaging VAS 581 009

1. Cut the packaging tape and remove the cardboard box. Keep the cardboard box in case you need to return the device.

2. Carefully remove the protective foil from the VAS 581 009.

3. Use the scissors/side cutter to cut the four zip ties used to additionally secure the VAS 581 009 to the pallet.

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Scope of delivery

WARNING

Danger of crushing

The VAS 581 009 can topple from the pallet.

4. Carefully lift the VAS 581 009 from the pallet with the help of another person.

Fig. 2-2

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Scope of delivery

3 Scope of delivery

No. VAS No.

Components

Item number

AVL DiTEST

VOLKSWAGEN

1. Basic device VAS 581 009

cplt.

VS9155

ASE VAS 581 009 00 000

2. Operating instructions on CD

BO7960

3. Unpacking instructions, placing into service instructions, quick start guide, printed

AT7912EN

4. Inspection log book, printed

AT7914EN

5. Quick connector CO2 HP red

GE7520

6. Quick connector CO2 LP blue

GE7522

7. Filling hose CO2 HP red

SS7520

8. Filling hose CO2 LP blue

SS7521

9. Cover

MK7532

10. Acceptance report

11. Cylinder adapter W21, 8x1/14" incl. seal for connecting the R744 cylinder to the VAS 581 009

Notice:

It is possible that the supplied cylinder adapter is not compatible with a cylinder available in your country. This is why we offer a variety of different adapters. See "Available accessories".

DN7469

12. Protective goggles

GE7432

13. Protective gloves

GE7435

14. Cylinder adapter seal

DA7451

15. Printing paper

HP7003

16. Power cable EU

EX7075

17. Heating tape

BV8313

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Placing into service

4 Placing into service

WARNING

Placing into service must be performed by qualified personnel under strict observance of these instructions.

4.1 Installation location / stability

WARNING

Make sure that the VAS 581 009:

 is horizontal and stable  is located in a room with adequate ventilation and/or air exchange  is at least 10 cm away from other objects  is protected against rain, excessive humidity, direct sunlight and/or excessive dust

 is not operated in explosive environments

CAUTION

Temperature equalisation

If the VAS 581 009 is delivered in winter, it must be ensured that no condensation can occur inside the device. This is why we request that you leave the device standing unplugged at the site of use for about three hours.

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Placing into service

4.2 Checking the vacuum pump oil

Check the oil level through the gauge glass. Top op with vacuum pump oil if necessary; see operating instructions, Sec. 5.2.1.

Fig. 4-1 Checking the vacuum pump oil

4.3 Power connection

Use the supplied power cable to connect the VAS 581 009. Connect the power cable to the power supply.

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Placing into service

4.4 Switching on the VAS 581 009

1. Apply the wheel brakes.

Fig. 4-2 Applying the wheel brakes

2. Switch on the VAS 581 009.

Fig. 4-3

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Placing into service

User interface

The user interface is controlled via a multi-functional dial. The individual functions (buttons) are selected by turning the dial. To start a function, the dial must be pressed.

Fig. 4-4

HP High Pressure

High pressure HP display of the refrigerating agent circuit

LP Low Pressure

Low pressure LP display of the refrigerating agent circuit

Multi-functional dial

To select and start a function, see below.

Operating modes

Automatic mode 

Operating instructions, Sec. 3 "Automatic mode"

Manual mode 

Operating instructions, Sec. 4 "Manual mode"

Settings 

Operating instructions, Sec. 5 "Settings"

Maintenance 

Operating instructions, Sec. 6 "Maintenance"

Service 

Operating instructions, Sec. 7 "Service"

Overview 

Operating instructions, Sec. 8 "Overview"

1 2 3

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Placing into service

User prompts

Selects previous function

Down

Selects next function

Back

Goes back one step.

Start

Starts functions.

Cancel

Cancels an ongoing operation. Confirms questions with "No".

RESET Resets values.

Confirms questions with "Yes" or "OK".

Continues to the next step.

Prints logs.

Text and number inputs

If a number or letter is expected as an input, turning the dial will show the letters and numbers in sequential order. Pressing the dial will select the letter or number.

Fig. 4-5 Example input

RESET

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Placing into service

Multi-functional dial

The multi-functional dial is equipped with an indicator. Meaning of the indicator:

Meaning

Indicator state

System start

Blue

Status OK / completed

Green

Ongoing process

Yellow

User information

Yellow flashing (1-2 Hz)

Error

Red flashing (1-2 Hz)

System error

Red fast flashing (10 Hz)

3. Self-test is being carried out automatically.

4. The following message appears after a successful self-test.

Fig. 4-6 Self-test successful

5. Continue with .

6. You are in the main menu.

Fig. 4-7 Main menu

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Placing into service

7. Tap Settings.

Fig. 5-8 Main menu - Settings

8. Tap Language.

Fig. 5-9 Settings - Language

9. Select your language.

Fig. 5-10 Language - Language selection

10. The VAS 581 009 restarts and performs a self-test after a language has been selected.

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Placing into service

4.5 Pressure zeroing

1. Select Maintenance in the main menu.

Fig. 4-11 Maintenance

2. Select Reset to zero.

Fig. 4-12 Pressure zeroing

3. Start pressure zeroing with .

Fig. 4-13 Pressure zeroing - Start Pressure zeroing takes about 60 seconds. The counter is displayed. Wait until

the process is complete.

4. "Pressure zeroing" is complete.

5. Exit "Pressure zeroing" with .

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Placing into service

4.6 Oil/UV additive scales zeroing

1. Select Reset Oil/UV additive scales to zero.

Fig. 4-14 Oil/UV additive scales zeroing

2. Start Oil/UV additive scales zeroing .

Fig. 4-15 Scales zeroing Follow the instructions on the display. (e.g. mount empty oil/UV additive

containers, etc.). Note: The mounted oil containers must be completely empty for zeroing. If this is not the case, an error message may occur during zeroing.

3. "Oil/UV additive scales zeroing" is complete.

4. Exit "Oil/UV additive scales zeroing" with .

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Placing into service

4.7 Connecting the refrigerating agent cylinder CO2 (R744)

NOTICE

The VAS 581 009 is suitable for standard CO2 (R744) refrigerating agent cylinders with a built-in riser tube. The following cylinder sizes can be used: 5 kg, 6 kg, 10 kg or 20 kg.

Required purity equal or better than carbon dioxide 3.0 (99.9% purity).

Refrigerating cylinders can vary in size and design depending on the country. In these instructions the two most common types are described.

1. Select Replace refrigerating agent cylinder in the maintenance menu.

Fig. 4-16 Replacing refrigerating agent cylinder

2. Now select Cylinder content.

Fig. 4-17 Replacing refrigerating agent cylinder

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Placing into service

3. Enter the weight of the cylinder content. (= nominal quantity of the content / nominal capacity of the cylinder, not the actual cylinder capacity!) Incorrect entries inevitably result in incorrect calculations of the available/usable cylinder capacity.

Fig. 4-18 Cylinder capacity

4. Select tare weight.

Fig. 4-19 Tare weight

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Placing into service

5. Refrigerating agent cylinder with protective cap: a) In order to read the tare weight, the protective cap must be removed from the

refrigerating agent cylinder.

Fig. 4-20 Protective cap

b) Note down the tare weight.

The tare weight represents the net weight of the used cylinder (empty). This weight is usually shown on the cylinder, sometimes embossed.

Fig. 4-21 Ttare weight

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Placing into service

c) Mark the location of the outlet valve on the refrigerating agent cylinder.

Fig. 4-22 Mark

d) Re-attach the protective cap.

Fig. 4-23 Protective cap

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Placing into service

6. Enter the tare weight.

Fig. 4-24 Tare weight

7. Press to continue replacing the cylinder.

Fig. 4-25 Start

8. Skip this message by clicking . The hose is automatically emptied.

Fig. 4-26 Unscrew the screw connection

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Placing into service

9. Continue with .

Fig. 4-27 Disconnecting the quick connectors

10. Continue with .

Fig. 4-28 Close manual valve

11. Continue with .

Fig. 4-29 Disconnecting refrigerating agent cylinder

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Placing into service

12. Follow the instructions. Make sure the scales are unladen.

Fig. 4-30 Information

13. Continue with .

14. Follow the instruction.

Fig. 4-31 Information

a) Attach the cylinder heater (heating band) around the lower third of the cylinder. Important: The closure of the cylinder heater must be located on the opposite side of the outlet valve.

Fig. 4-32 Heating band

Outlet valve

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Placing into service

b) Make sure that the cylinder heater (heating band) is connected.

Fig. 4-33 Connecting heating band c) Place the new refrigerating agent cylinder onto the refrigerating agent scales.

Note that the bottle heating cable is not placed on the balance during the assembly of the bottle. Attach the securing chain.

Fig. 4-34 Securing chain

15. Continue with .

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Placing into service

16. Refrigerating agent cylinder with protective cap: Remove the protective cap. Make sure that the connection of the refrigerating agent cylinder is facing the device and not away.

Fig. 4-35 Information

17. Zeroing and hose emptying are performed automatically.

Fig. 4-36 Refrigerating agent cylinder

18. Remove the hose from the plastic cap if necessary.

Fig. 4-37 Plastic cap

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Placing into service

19. Remove the plastic cap on the outlet valve if necessary.

Fig. 4-38 Refrigerating agent cylinder with Plastic cap

20. Attach the supplied cylinder adapter. Torque: 30 … 32 Nm, max. 35 Nm.

Fig. 4-39 Refrigerating agent cylinder with cylinder adapter

21. Connect the hose to the cylinder adapter. Spanner width: 14 mm

Torque: 16 … 18 Nm, max. 20 Nm.

Fig. 4-40 Connect the hose to the cylinder adapter

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Placing into service

22. Continue with .

23. Make sure that the hose/hose connection is facing the device. It must not lead away from the rear of the device. This could lead to a faulty measurement of the cylinder weight.

Fig. 4-41 Hose connection

24. Follow the instructions and open the manual valve of the refrigerating agent cylinder.

Fig. 4-42 Information

Fig. 4-43 Manual valve





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Placing into service

25. End the replacement of the refrigerating agent cylinder with . The system is flushed with CO2, i.e. the filling hoses are first flooded with CO2,

then the CO2 is discharged. The VAS 581 009 must not be connected to the vehicle at this time.

26. Exit the menu with .

27. Select to return to the main menu.

28. The VAS 581 009 is now ready for use.

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Available accessories

5 Available accessories

No.

VS No.

Components

Item number

AVL DiTEST

VOLKSWAGEN

1. Vacuum pump oil 500 ml

(2 units per package)

GE7427

2. Printer paper 57 mm, (minimum order quantity: 5 units

HP7003

3. Cylinder heater (heating band) incl. connector

BV8261

4. External pressure test set

BO7948

Cylinder adapter incl. seal: W21.7x1/14"

DN7470

Cylinder adapter incl. seal:

0.860"x14TPI

DN7471

Cylinder adapter incl. seal: G3/4"

DN7472

Cylinder adapter incl. seal:

0.825"x14NGO

DN7473

Cylinder adapter incl. seal: W27x2mm

DN7474

10. Calibration kit BAS 581 009

BO7972

WARNING

Only use accessories approved by AVL DiTEST!

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Quick start guide

6 Quick start guide

OBSERVE SAFETY INSTRUCTIONS

Wear personal protective equipment!

Switch on VAS 581 009; Self-test runs automatically.

Select "Automatic cycle" in main menu.

Enter parameters:

- Configuration name

- Refrigerating agent [g]

- Oil quantity [g]

- Oil filling mode [REC+/ABS/NO]

- UV additive quantity [g]

- Vacuum time [min]

- Vacuum test time [min]

- Connection type [LP / HP+LP]

- Pressure test [OFF / 10% / 20%]

- Pressure test time [min]

- Pressure loss [mbar]

- Customer data

Check and confirm inputs

Connect quick connectors with vehicle and confirm Open gas supply of quick connectors

"Automatic cycle" runs automatically

Automatic cycle

- Safety self-test

- Drain refrigerating agent

- Vacuum generation

- Filling of air conditioning system

Close gas supply of quick connectors and confirm. Hoses are emptied in VAS 581 009.

Disconnect quick connectors from vehicle and confirm. Print report [Yes/No]

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Quick start guide

Selects previous function

Down

Selects next function

Back

Goes back one step.

Start

Starts functions.

Cancel

Cancels an ongoing operation.

Confirms questions with "No".

RESET

Resets values.

Confirms questions with "Yes" or "OK".

Continues to the next step.

Prints logs

Text and number inputs If a number or letter is expected as an input, turning the dial

will show the letters and numbers in sequential order. Pressing the dial will select the letter or number.

RESET

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Fault conditions

7 Fault conditions

In the case of an error, please proceed as follows:

 Try to determine the cause and location of the error. Please refer to the

"Troubleshooting" section in the operating instructions before contacting your service partner.