Volkswagen VAS 531 009 User manual

Operations manual
CO2 coolant tester VAS 531 009
Operations manual
CO2 coolant tester VAS 531 009
Volkswagen Aktiengesellschaft
K-GVO-LW
Group After Sales – Group Service, Literature
and Systems
Workshop Equipment
Letter Box 011/4915
38442 Wolfsburg
For internal use only
Technical amendments possible
Status 01/2021
Volkswagen Aktiengesellschaft
K-GVO-LW
Group After Sales – Group Service, Literature
and Systems
Workshop Equipment
Letter Box 011/4915
38442 Wolfsburg
For internal use only
Technical amendments possible
Status 01/2021

Manufacturer: AVL DiTEST GmbH
Alte Poststraße 156
A-8020 Graz
AUSTRIA
AVL ID-No: AT8033EN_US
Rev. 01
For more than 20 years, AVL DiTEST has been developing integrated solutions for the automotive after sales sector and equips work-
shops and test centers in more than 50 countries worldwide. The main business areas of AVL DiTEST are measurement technology,
emission testing, automotive diagnostics, air conditioning service and e-mobility. In Europe, the developments of the Austrian-Ger-
man automotive diagnostics and measurement technology specialist are considered the technological benchmark. The research and
development ratio is an outstanding 20%. Testing organizations such as Dekra or TÜV, as well as leading automobile manufacturers,
including Volkswagen AG, rely on the technical know-how from Graz and Cadolzburg.
AVL DiTEST is part of the AVL Group. The company, together with its international subsidiaries, employed 320 people in 2019 and
generated annual sales of € 57.4 million in 2019.
Contents
Introduction 5
Content Of The Operations Manual 5
Intended Use 5
Target Group 5
Safety 6
IMPORTANT SAFETY INSTRUCTIONS 6
Danger Warnings 7
Safety Concept 7
Scope Of Delivery 9
Available Accessories 9
Illustration Of The Scope Of Delivery 10
Assembly 11
Signals 12
Commissioning 13
Installation Of The Software 13
Hardware 13
Measurement 14
Maintenance 15
Visual Inspection 15
Cleaning 15
Software Update 15
Troubleshooting 16
Technical Data 18
Disposal 18
Declaration Of Conformity 19
Index 20
Contents

6 | Safety5 | Introduction
This documentation describes the VAS 531 009 CO2 coolant tester and how to use it. The safety instructions in the Safety chapter and the
remainder of the operations manual have to be strictly complied with.
This document is an integral part of the equipment. Store it for the life of the equipment and pass it on to any subsequent owners or users.
Target Group
This manual contains important warnings and safety instructions that require attention by the user. Non-compliance with these warnings
may result in death or serious injury.
SafetyIntroduction
Content Of The Operations Manual
Intended Use
The VAS 531 009 CO2 coolant tester , herein after referred to as CO2 coolant tester , measures the CO2 content in the expansion tank of the
engine cooling system An increased CO2 content in the cooling system indicates leaks from between the exhaust system and the cooling
system. During the measurement, minimum/maximum values and the time progression of the CO2 content and the cooling system pres-
sure are displayed. A result report can be printed out and saved at the end of the measurement.
The
CO2 coolant tester is intended for motor vehicle repair/service workshops or similar institutions.
INFORMATION For more information, please contact your importer.
Comply with the regulations applicable in your country.
Read and follow these operations manual.
IMPORTANT SAFETY INSTRUCTIONS
– Read the operations manual completely and carefully.
– In the event that the equipment is dropped or damaged, have it checked by a qualied service technician before starting operation
again.
– Ensure that cables are not stretched or kinked or come into contact with sharp edges.
– Do not allow the equipment to come into contact with hot or moving parts.
– Always disconnect the equipment from the USB port when not in use.
– Pull on the plug and not the cable to remove the plug from the USB port.
– Allow the equipment to cool down completely before putting it away.
– When storing the equipment, lay the hoses loosely around the equipment.
– When storing the equipment, always store it in the case provided.
– To reduce the risk of re, do not operate the equipment near open containers with ammable liquids (e.g. gasoline).
– Ensure adequate ventilation when working on combustion engines.
– Keep hair, loose clothing, ngers and all body parts away from moving parts.
– To reduce the risk of electric shock, avoid using the equipment on wet surfaces or exposing it to rain.
– Operate the equipment only as described in this manual.
– Only use accessories recommended by the manufacturer.
– ALWAYS WEAR SAFETY GLASSES. Everyday eyeglasses only have impact resistant lenses, they are not safety glasses.
– Perform all work in the engine compartment with the engine stopped and the ignition switched o.
– Do not come into contact with rotating parts such as the alternator, the radiator fan and their drives (e.g. V-belts).
– When the engine is running, make sure that the hoses and wiring are routed safely.
– Apply the handbrake or, with an automatic transmission, move the selector lever to P.
– Secure the vehicle adequately against rolling away.
– Care must be taken as burns can occur from touching hot parts.
SAVE THESE INSTUCTIONS

8 | Safety7 | Safety
Ad quam cum nosandae nos min rest, sed
Danger Warnings
WARNING indicates a dangerous situation which, if not avoided, can lead to death or serious
injury.
Danger from hot liquids and high pressure.
This text refers to important information or instructions. Failure to follow these
instructions will signicantly prevent or hinder the successful execution of the actions
described in this documentation.
WARNING
WARNING
INFORMATION
NOTE This text refers to situations or operating errors that can lead to damage to property or
data loss.
Safety Concept
Risk of burns from hot parts
Carry out measurements at normal engine operating temperature or according to the test
specication. Do not touch hot parts like the engine, engine attachments and the entire
exhaust system. Use cooling fans if necessary.
WARNING
Ad quam cum nosandae nos min rest, sed
Risk of injury from damaged components
Place the measuring system, especially the hoses and wiring, in a way that no damage can
occur during operation by hot parts (exhaust system) and rotating parts (drive belts, radiator
fans, etc.).
Risk of burns from hot liquids and high pressure
While the cooling system is under pressure, hot coolant can splash out when the
expansion tank is opened.
Only open the cover of the expansion tank (coolant tank) when the coolant has cooled
down.
Risk of injury due to material damage
The measuring system is under high pressure during application and is subject to the
temperatures of the cooling system. Pre-damage to the measuring system can lead to
a risk of injury during operation.
During storage, always keep the measuring system in the equipment case supplied
with it and protect it from harmful environmental inuences. In particular, this
prevents the material from being negatively aected by UV radiation.
WARNING
WARNING
WARNING
WARNING Risk of explosion and/or re
The equipment must not be operated near open fuel tanks or below a minimum
height of 460 mm above the workshop oor, otherwise there is a risk of explosion or
re due to gases and/or vapors.
Ad quam cum nosandae nos min rest, sed
Sensitive measurement technology is built into this equipment. Falls – even from a low
height and impacts can damage the measurement technology and falsify results. In the
event that the equipment is dropped or damaged, have it checked by a qualied service
technician before starting operation again.
NOTE
Ad quam cum nosandae nos min rest, sed
If the measuring system is pre-damaged, a loss of pressure can cause the cooling system of
the vehicle to boil over and cause engine damage.
During storage, always keep the measuring system in the equipment case supplied with it
and protect it from harmful environmental inuences. In particular, this prevents the materi-
al from being negatively aected by UV radiation.
NOTE

10 | Scope of Supply9 | Scope of Supply
The following accessories can be ordered as options:
USB cable Mini - "Fischer" (for connecting the CO2 coolant tester to the VAS
equipment using a “Fischer” socket, reference: VAS 5055/4)
Scope Of Delivery
The system delivery comprises of the following components:
VAS no. Components Article number
VAS 531 009 CO2 coolant tester with coolant adapter and hose
kit
ASE 531 009 00 000
- Transport and storage case -
- USB cable Mini - Type A 1.8 m -
- USB stick with:
- Documentation
- Software
-
- Quick start, printed -
- Information sheet USB stick, printed -
The following table shows an illustration of the individual components:
Components Photo
ASE 531 009 00 000
CO2 coolant tester with coolant adapter and hose kit
Transport and storage case
USB cable Mini – Type A 1.8 m
USB stick with documentation and software
Quick start, in printed format
Information sheet USB stick
Illustration Of The Scope Of Delivery
Available Accessories
NOTE Only use accessories approved by AVL DiTEST.

12 | Signals11 | Assembly
Assembly
A LED is installed on the equipment that signals the operating state of the equipment. The following table provides an overview of the
dierent states of the LED and explains their meaning:
Signals
The following illustration shows the conguration of the equipment:
2
6
5
1 Mountings
2 Safety valve
3 LED red/green
4 2 hoses, permanently connected to VAS 531 009 and the coolant adapter
5 Coolant adapter
6 Mini USB port
7 Inspection window (for intake coolant)
LED state Meaning
Green
Constantly lit
The system is ready to start a measurement
Green
Slowly lashing
Measuring process active
Green
Quick lashing
Pump activated
Red
Constantly lit
CO coolant tester is not in normal position
Red
Flashing
A malfunction occurred. In this case, the software
displays an error message which shows more
detailed information
7
1
3
4

14 | Measurement13 | Commissioning
Commissioning
Hardware
Proceed as follows to install the software:
1. Start the tester/specied laptop.
2. Insert the USB stick with the software into a free USB port.
→ If Autorun is activated, then the installation program starts automatically.
→ If Autorun is not activated, double click on le Install.CO2ContentCheck.x.x.xxxx.msi.
3. If required, enter the user name of the administrator and the password and click Yes.
→ The les are imported and installed.
4. In the next window click Next.
5. Click Finish.
6. Perform a restart of the specied laptop.
The software was successfully installed.
Connect theCO2 coolant tester using the USB cable (Type A – Mini or Type A – "Fischer") to the tester/specied laptop.
To perform a measurement proceed as follows:
Measurement
Installation Of The Software
INFORMATION First install the software and then connect the CO2 coolant tester to the tester/speci-
ed laptop. Administrator rights are required for the installation.
NOTE When the CO2 coolant tester is delivered, condensation must be prevented inside the
equipment. Leave the equipment to stand for 3 hours at the operating location for
temperature compensation before switching it on.
INFORMATION First install the software and then connect the CO2 coolant tester to the tester/speci-
ed laptop. Administrator rights are required for the installation.
Risk of burns from hot engine and coolant
Ensure that the engine is switched o and that the engine and coolant have cooled down.
WARNING
1. Open the engine hood.
2. Hang the CO2 coolant tester on a raised point using the suspension bracket. The CO2 coolant tester must be in normal position, i.e.
hanging vertically. Do not place the CO2 coolant tester in the engine compartment or elsewhere.
Risk of burns from hot liquids
Only open the cover of the expansion tank (coolant tank) when the coolant has cooled down.
WARNING
3. Unscrew the cover of the expansion tank (coolant tank) and install the coolant adapter. Make sure that the coolant adapter is tightly
tted on the thread.
4. Start the CO2 coolant tester by double-clicking CO2 Content Check .
5. Click on CO2 Test. (With Display equipment data the data of the CO2 coolant tester is shown).
6. Follow the instructions on the screen and comply with and conrm all safety instructions.
At the end of the measuring sequence, a result protocol appears with the measured values (CO2 and cooling system pressure) and a graphic
representation of the CO2 and cooling system pressure curve. This results report can be printed out and saved.
NOTE Always observe the vehicle-specic repair information provided by the manufacturer.

16 | Troubleshooting15 | Maintenance
Maintenance
Perform a visual inspection regularly. Check for:
– Gross contamination
– Wear
– Check all parts regularly for damage
– Damage and leakage of the media lines
If parts are damaged, contact AVL DiTEST Service:
Troubleshooting
Visual Inspection
Phone: [phone] Germany
[phone] International
FAX: [phone]
E-Mail: vas[email protected]
Cleaning
Clean the equipment if it is dirty.
NOTE The equipment must not be under pressure during cleaning.
Make sure that no liquid enters the housing.
NOTE Do not use a high-pressure cleaner or caustic cleaning agents to clean the equipment.
Wipe the CO2 coolant tester with a lint-free cloth.
The cloth can be moistened with water or an alkali-free cleaning agent. It can be moist but not wet.
Software Update
The software may need to be updated. Get regular information from Volkswagen AG about the current version of your DSS software.
This chapter provides an overview of potential errors that may occur in the hardware. If there are other errors, the software will display
error messages that are not included in this chapter. If this is the case, follow the solutions shown on the screen and carry out all the
measures oered.
If an error cannot be eliminated, contact the AVL DiTEST Service:
E-Mail: vas[email protected].
The following table lists potential errors in the hardware and their possible causes and solutions:
Symptoms Possible causes Solution
CO2 coolant tester does not start, LED does not
light up
The CO2 coolant tester is incorrectly connected to
the PC.
Ensure that the USB cable is plugged in at both
ends. The LED is green when correctly connected.
If the error persists, contact the AVL DiTEST Service.
Connection between the CO2 coolant tester and
the PC system is interrupted
The CO2 coolant tester is incorrectly connected to
the PC.
Ensure that the USB cable is plugged in at both
ends. The LED is green when correctly connected.
If the error persists, contact the AVL DiTEST Service.
The LED lights up red constantly The equipment is not in normal position. The
equipment has not been attached in the center of
the suspension bracket.
Attach the CO2 coolant tester centrally to the
suspension bracket.
Plug does not it in socket Wrong cable or wrong cable side. Use the correct cable or insert the appropriate plug
into the correct socket.

18 | Technical Data17 | Troubleshooting
Technical Data
General data
Dimensions 185x300x65 mm (without coolant adapter)
Weight About 3.2 kg
Power supply via USB interface of tester/speciied laptop
Display LED green
LED red
PC interface USB cable, 1.8 m length
Hose length to coolant adapter 1.5 m
Climatic conditions
Operating temperature +5 ... +45 °C
Storage and transport temperature -40 ...+70 °C
Air humidity Operation: up to 80 % non condensing
Storage: up to 100 % non condensing
Measured values
Measuring range 400 … 10,000 ppm
Pressure measuring range 0 … 1.6 bar [rel.]
The following hardware errors are indicated by the software:
Symptoms Error message/description Solution
LED lashes red Pump overlow The hoses and/or the equipment
have illed with liquid or are blocked.
Stop operation and drain the liquid or remove the
blockage. If this is not possible, contact AVL DiTEST
service.
LED lashes red Operating temperature too high. The equipment is
used in a hot environment.
Stop the operation and let the equipment cool
down to 45 °C.
LED lashes red Operating temperature too low. The equipment is
used in a cold environment.
Operate the equipment in an environment of at
least 5 °C.
LED lashes red 5 V voltage supply outside of tolerance range.
Possible causes:
•The USB plug is dirty or corroded.
• The equipment is operated at the USB hub at the
same time as other equipment.
Check the USB connector and replace the cable if
necessary. Connect the equipment to a separate
USB port on the PC or supply the USB hub with a
separate power supply.
Software displays error message "Too little pressure
increase or too little pressure in the cooling system
detected!”
The engine cooling system or the measuring
system is leaking.
Stop the operation and the engine and let the
cooling system cool down. Check the engine and
measuring system for leaks. If necessary, contact
the AVL DiTEST service.
Software displays the error message "Calibration of
CO2 sensor necessary”
The CO2 sensor must be recalibrated. Contact the AVL DiTEST service.
Software displays the error message "Overpressure
in cooling system detected!”
There is a defect in the engine cooling system (e.g.
a defective cylinder head gasket or the radiator fan
does not work).
Switch off the engine immediately and let the
system cool down before taking further steps.
Check the engine cooling system and correct any
malfunctions before starting a new measurement.
When the system stops responding, it is a fault in the CO2 coolant tester or the application running on it. Try to exit and restart the
software. If this is not possible, plug the equipment in again and again.
This AVL DiTEST product is a high quality electrical and electronic device that should not be disposed of with household
waste.
When disposing of it, local legal requirements must be met.
Disposal

20 | Index19 | Declaration of Conformity
A
Assembly 11
C
Cleaning 15
Cleaning Agents 15
Climatic Conditions 18
Commissioning 13
Components 9
D
Danger Warnings 7
G
General Data 18
I
Installation 13
Intended Use 5
L
LED 12
M
Measured Values 18
O
Operating Temperature 18
P
Power Supply 17
Pump Overow 17
S
Safety Instructions 6
T
Target Group 5
Temperature Compensation 13
V
Visual Inspection 15
Index
Declaration Of Conformity
This product meets all relevant guidelines, directives, standards, etc.
The complete text of the EC Declaration of Conformity can be found in the Internet under:
https://www.avlditest.com/index.php/de/downloads-de.html
EU –KONFORMITÄTSERKLÄRUNG
EU –DECLARATION OF CONFORMITY
Referenced Document: Checklist DoC VAS531009
Wir,
We
Hersteller:
AVL DiTEST GmbH
Manufacturer:
Anschrift:
A-8020 GRAZ, Alte Poststrasse 156
Address:
erklären, auf Basis des in der Anlage referenzierten Dokument, in alleiniger Verantwortung, dass das
von AVL DiTEST GmbH hergestellte Produkt
declare, based on the referenced document, see annex under our sole responsibility, that the product
produced at AVL DiTEST, called
***VAS 531 009***
BO8044 / VS9223
in Übereinstimmung mit den Bestimmungen der nachstehenden EU-Richtlinien ist
in accordance with the regulations of the following EU-directives
2014/30/EU
Richtlinie des Rates zur Angleichung der Rechtsvorschriften der Mitgliedstaaten
über die elektromagnetische Verträglichkeit
Council Directive on the approximation of the laws of the Member States
relating to electromagnetic compatibility
2011/65/EU
Richtlinie des Rates zur Beschränkung der Verwendung bestimmter Stoffe in
Elektro- und Elektronikgeräten
Council Directive on the restriction of the use of certain hazardous substances
in electrical and electronic equipment
und dass folgende harmonisierten Normen zur Anwendung gelangt sind:
and the following harmonized standards were applied:
EN 61326-1:2013
Electrical equipment for measurement, control and laboratory use - EMC
requirements -- Part 1: General requirements
EN 50581:2013
Technical documentation for the assessment of electrical and electronic products
with respect to the restriction of hazardous substances
Graz, 31.07.2020
DI Anton Kohl
Entwicklungsleiter
Director R & D
Mag.(FH) Kurt Leitinger
Leiter Operations
Director Operations

We have checked the content of the documentation for compli-
ance with the described status. However, deviations cannot be
excluded so that we cannot guarantee complete conformity. The
information in this documentation is, however, checked regularly
and necessary corrections are included in subsequent editions.
We are grateful for suggestions for improvement.
Changes to the scope of delivery in form, equipment and tech-
nology are possible. The information, illustrations and descrip-
tions in this operating manual can therefore not be taken as a
basis for claims. Reproduction, duplication or translation, even in
part, is only permitted without the written approval of the Volk-
swagen Group/the manufacturer in such a way that user docu-
mentation is provided for each equipment. A passing on to third
parties is not permitted. All rights under the German Copyright
Act are expressly reserved by the Volkswagen Group and the
manufacturer.
Subject to change without notice.