Bosch ACS 511 Repair Instruction Download | Manualshive

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ACS 511

en

Repair instruction

A/C Service Unit

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Summary of Contents for ACS 511

Page 1: ...ACS 511 en Repair instruction A C Service Unit ...

Page 2: ...ressor oil 21 8 10 Non condensing gases 22 9 Troubleshooting 23 9 1 Service messages 23 9 2 Fault messages 23 10 Emptying the ACS 511 24 10 1 Automatic emptying 24 10 2 Extraction of internal refrigerant circuit with sec ond A C service unit 24 11 TROUBLESHOOTING AND ANALYSIS 25 11 1 Faults during recovery 25 11 1 1 Compressor starts 25 11 1 2 Compressor does not start 25 11 1 3 Fault messages tha...

Page 3: ...y CAUTION Possible dangerous situation Minor injury 1 1 2 Symbols in this documentation Symbol Designation Explanation Attention Warns about possible property damage i Information Practical hints and other useful information 1 2 Multi step operation Instruction consisting of several steps e One step operation Instruction consisting of one step Intermediate result An instruction produces a visible ...

Page 4: ...e requirements of the electrical engineering directives were adhered to To check this tests should be performed the nature and extent of which are based on the measures specified in the electrical engineering directives e g in Germany DGUV Vorschrift 3 The type and extent of the tests are described in VDE 0701 0702 Part 1 within Germany The relevant national directives must be complied with 3 Test...

Page 5: ... cant dirt and traces of other gases R R R134a is not to be used in areas in which there is a danger of explosion Fire naked flames and smok ing are prohibited Welding and soldering are not permitted R R High temperatures and UV radiation may chemically separate the R134a The resultant products cause coughing and nausea R R R134a is not to be mixed with other refrigerants The mixing of refrigerant...

Page 6: ...t scales at least once per year Please contact cus tomer service 4 6 Safety devices For safety reasons it is advisable to use a residual current operated circuit breaker rccb with the fol lowing specifications Parameters Specification Rated voltage 230 VAC 10 Rated frequency 50 60 Hz Rated current 230 VAC 10 A Rated tripping current 30 mA Tripping switch C Overview of safety devices Description Op...

Page 7: ...tle 10 Used oil bottle 11 Cover 12 Front wheels with locking brake i i The high 6 and low pressure 5 gages show the current pressure during the air conditioning service on the vehicle The small gage 7 is used to check the bottle pressure in the internal refrigerant cylinder i i The two valve settings are labeled as follows C closed valve is closed O open valve is open 5 1 2 Rear view 1 5 4 3 2 6 7...

Page 8: ... Control right R R Filling R R Cursor movement to the right R R Vehicle air conditioning system is filled with refrigerant R R Control left R R Automatic R R Cursor movement to the left R R Automatic service run Air condi tioning service is carried out ac cording to saved parameters R R Control down R R Flushing R R Downward cursor movement R R Flush components of the vehicle air conditioning Menu...

Page 9: ...IL 6 4 Vehicle and customer data Input Menu 1 Menu 2 Database STANDARD SPECS EUROPEAN DATABASE USER SPECS SELECT MODEL DELETE MODEL ADD MODEL VEHICLE DATAS 6 5 Menu Input Menu 1 Menu 2 Menu PERFORMANCE TESTS DIAGNOSTIC TANK FILLING TANK RECYCLING ZEROING OIL SCALES REPORT MANAGEMENT PRINT REPORT EXPORT DATA DELETE DATA 6 6 Manual mode Input Menu RECOVERY R R Automatic emptying R R Extraction R R O...

Page 10: ...ow solenoid valve Name Description EV5 Recovery solenoid valve EV6 Filling solenoid valve EV7 Oil drain solenoid valve EV8 Oil injection solenoid valve EV9 Contrast medium injection sole noid valve EV10 Solenoid valve for separating high and low pressure F1 Coarse filter F2 Combi filter HP High pressure LP Low pressure M1 Low pressure gage M2 High pressure gage M3 Internal refrigerant cylinder pre...

Page 11: ...nt The solenoid valves EV10 EV3 and EV5 are opened and the compressor 6 is started R R The refrigerant flows through the solenoid valves EV 10 EV3 and EV5 the mechanical filter F1 the expansion valve 3 and the condenser separator 4 R R The expansion valve maintains a constant pressure at the evaporator oil separator 4 R R In the evaporator oil separator 4 the oil extracted from the vehicle air con...

Page 12: ...id valve Name Description EV5 Recovery solenoid valve EV6 Filling solenoid valve EV7 Oil drain solenoid valve EV8 Oil injection solenoid valve EV9 Contrast medium injection sole noid valve EV10 Solenoid valve for separating high and low pressure F1 Coarse filter F2 Combi filter HP High pressure LP Low pressure M1 Low pressure gage M2 High pressure gage M3 Internal refrigerant cylinder pres sure ga...

Page 13: ... Refrigerant cylinder scales 9 Used oil bottle 10 Heat exchanger 11 UV dye bottle 12 Fresh oil scales 13 Used oil scales EV1 Vacuum solenoid valve EV3 Flow solenoid valve Name Description EV5 Recovery solenoid valve EV6 Filling solenoid valve EV7 Oil drain solenoid valve EV8 Oil injection solenoid valve EV9 Contrast medium injection sole noid valve EV10 Solenoid valve for separating high and low p...

Page 14: ...e the vehicle air conditioning system is empty and the ACS 511 starts vacuum generation i i If the pressure is above the set value there is still re frigerant in the vehicle air conditioning system and it must be extracted before vacuum generation 3 Press the Vacuum key EV1 and EV10 are opened and the vacuum pump 2 starts i i The vacuum pump generates a maximum vacuum of 0 05 mbar This depends on ...

Page 15: ...EV9 Contrast medium injection sole noid valve EV10 Solenoid valve for separating high and low pressure F1 Coarse filter F2 Combi filter HP High pressure LP Low pressure M1 Low pressure gage M2 High pressure gage M3 Internal refrigerant cylinder pres sure gage Name Description P1 Pressure sensor P2 Pressure switch T1 Low pressure hose T2 High pressure hose V1 Tank vapour side hose valve V2 Tank liq...

Page 16: ...nder 8 Refrigerant cylinder scales 9 Used oil bottle 10 Heat exchanger 11 UV dye bottle 12 Fresh oil scales 13 Used oil scales EV1 Vacuum solenoid valve EV3 Flow solenoid valve Name Description EV5 Recovery solenoid valve EV6 Filling solenoid valve EV7 Oil drain solenoid valve EV8 Oil injection solenoid valve EV9 Contrast medium injection sole noid valve EV10 Solenoid valve for separating high and...

Page 17: ...7 Internal refrigerant cylinder 8 Refrigerant cylinder scales 9 Used oil bottle 10 Heat exchanger 11 UV dye bottle 12 Fresh oil scales 13 Used oil scales EV1 Vacuum solenoid valve EV3 Flow solenoid valve Name Description EV5 Recovery solenoid valve EV6 Filling solenoid valve EV7 Oil drain solenoid valve EV8 Oil injection solenoid valve EV9 Contrast medium injection sole noid valve EV10 Solenoid va...

Page 18: ...1 EV8 EV9 13 active Name Description 1 Fresh oil tank 2 Vacuum pump 3 Expansion valve 4 Evaporator oil separator 5 Compressor oil separator 6 Compressor 7 Internal refrigerant cylinder 8 Refrigerant cylinder scales 9 Used oil bottle 10 Heat exchanger 11 UV dye bottle 12 Fresh oil scales 13 Used oil scales EV1 Vacuum solenoid valve EV3 Flow solenoid valve Name Description EV5 Recovery solenoid valv...

Page 19: ...ive Name Description 1 Fresh oil tank 2 Vacuum pump 3 Expansion valve 4 Evaporator oil separator 5 Compressor oil separator 6 Compressor 7 Internal refrigerant cylinder 8 Refrigerant cylinder scales 9 Used oil bottle 10 Heat exchanger 11 UV dye bottle 12 Fresh oil scales 13 Used oil scales EV1 Vacuum solenoid valve EV3 Flow solenoid valve Name Description EV5 Recovery solenoid valve EV6 Filling so...

Page 20: ...ompressor 7 Internal refrigerant cylinder 8 Refrigerant cylinder scales 9 Used oil bottle 10 Heat exchanger 11 UV dye bottle 12 Fresh oil scales 13 Used oil scales EV1 Vacuum solenoid valve EV3 Flow solenoid valve Name Description EV5 Recovery solenoid valve EV6 Filling solenoid valve EV7 Oil drain solenoid valve EV8 Oil injection solenoid valve EV9 Contrast medium injection sole noid valve EV10 S...

Page 21: ...cylinder scales 9 Used oil bottle 10 Heat exchanger 11 UV dye bottle 12 Fresh oil scales 13 Used oil scales EV1 Vacuum solenoid valve EV3 Flow solenoid valve Name Description EV5 Recovery solenoid valve EV6 Filling solenoid valve EV7 Oil drain solenoid valve EV8 Oil injection solenoid valve EV9 Contrast medium injection sole noid valve EV10 Solenoid valve for separating high and low pressure F1 Co...

Page 22: ...sor oil separator 6 Compressor 7 Internal refrigerant cylinder 8 Refrigerant cylinder scales 9 Used oil bottle 10 Heat exchanger 11 UV dye bottle 12 Fresh oil scales 13 Used oil scales EV1 Vacuum solenoid valve EV3 Flow solenoid valve Name Description EV5 Recovery solenoid valve EV6 Filling solenoid valve EV7 Oil drain solenoid valve EV8 Oil injection solenoid valve EV9 Contrast medium injection s...

Page 23: ...e scale settings Tare the scales HIGH RECOVERY TIME The recovery time exceeds the set maximum duration Check vehicle air condi tioner for leaks If error persists contact customer service A C SYSTEM EMPTY There is no refrigerant in the vehicle air conditioning system OUTOIL BOTTLE FULL CALIBRATE SCALE The used oil bottle is full and must be emptied OIL IN BOTTLE EMPTY FILL BOTTLE The fresh oil bott...

Page 24: ...Automatic emptying is performed 10 2 Extraction of internal refrigerant cir cuit with second A C service unit i i If recovery cannot be performed due to a defective compressor a second A C service unit or an external compressor is required to remove the refrigerant from the internal refrigerant circuit To do this start the Recycle function to open the corresponding solenoid valves i i The compress...

Page 25: ...Power applied Solenoid valve defective Clean or replace solenoid valve No voltage applied Computer PCB control PCB defective Replace computer PCB control PCB If the pressure at the pressure gages falls slowly 1 Check filter F 1 If clogged clean with compressed air blow out 2 Check function of valve VU2 3 Valves V1 and V3 must be open 4 Check expansion valve 3 with a pressure gage Op erating pressu...

Page 26: ... air conditioning system 1 Disconnect service hoses from vehicle 2 Open HP and LP valves 3 Check whether the hose connected to the vacuum pump is correctly connected at both ends and is not clogged 4 Check the oil level in the vacuum pump i i The oil level should be in the middle of the sight glass between the full and empty marks 5 Check the pump vacuum output the pressure must fall to less than ...

Page 27: ...t is soiled or clogged i i If the compressor does not start make sure that a supply voltage is connected to the compressor If no voltage is applied check the supply leads and the switching operation of the compressor relay 11 4 Non condensing gases are not drai ned Mechanically test drain valve V6 11 5 Faults during filling with refrigerant 11 5 1 Vehicle air conditioning system cannot be filled 1...

Page 28: ...2 must be used 12 3 Pressure switch P2 i i The pressure switch is normally closed between contacts 1 and 2 and open between contacts 1 and 4 The pressure switch opens at 16 bar To check the pressure switch carry out the following steps 1 Close V1 V4 2 Remove the red hose from the internal refrigerant cylinder and connect the red service hose to the internal refrigerant cylinder 3 Close both valves...

Page 29: ...he sealing rings when fitting a new filter Take care not to damage any hoses or electrical con nections when changing the filter Never re use an old filter Observe the ACS 511 menu prompting 1 Call up start screen 2 Open the HP and LP valves on the display and control panel 3 Press Recovery ACS 511 performs a self cleaning process then the recovery phase i i Pressure gauge must reach 0 bar 4 Close...

Page 30: ...ified by Bosch 1 3 2 Fig 5 Vacuum pump 1 Sight class 2 Oil fill plug 3 Drain plug Do not use excessive force when securing and re moving the oil drain and oil filling screw i i The container for catching oil should have a capacity of approx 1 l 1 Place a vessel under the drain 2 Remove drain plug and oil fill plug from vacuum pump 3 Drain off all the oil 4 Screw on drain plug finger tight 5 Fill i...

Page 31: ...alue and confirm with E The menu containing the functions appears on the display again i i Return with Stop 13 2 Fresh oil bottle scales i i According to the display the calibration weight must be entered in ml However we recommend enter ing the weight in grams Because of the density of 1 0 kg m 250 g corresponds to a value of 250 ml 1 Call up the start screen 2 Press 3 and Flush simultaneously an...

Page 32: ... menu containing the functions appears on the display again i i Return with Stop i i The used oil scales can also be calibrated without a calibration weight by filling the used oil bottle with oil and entering the exact measured total weight of the used oil bottle 13 4 Tara values The following Tara values for the Internal refrigerant cylinder and oil bottles are set from the factory Internal refr...

Page 33: ... the simulator until a volt age of 0 V is displayed 9 Enter the value 0 000 on the keypad and confirm with E WEIGHT CALIBRATION is displayed 10 Turn the potentiometer on the simulator until a voltage of 3 00 V is displayed 11 Enter the value 4 800 on the keypad and confirm with E The menu containing the functions appears on the display again 12 Remove the simulator and re connect the pressure sens...

Page 34: ... been called up the compressor starts 5 Press E to actuate the components in turn The values switch in the following order Compressor Vacuum pump Solenoid valve EV1 EV2 EV2 not used Solenoid valve EV3 EV4 EV4 not used Solenoid valve EV5 Solenoid valve EV6 Solenoid valve EV7 Solenoid valve EV8 Solenoid valve EV9 Solenoid valve EV10 i i Return with Stop 14 3 Control PCB input signal Follow the addit...

Page 35: ... and release The message ENTER CODE 0000 is displayed 3 Enter 1515 and confirm with E 4 Select SERVICE PRINTING with o u and con firm with E i i Return with Stop The following data appears in the service print out Total quantity of refrigerant recovered Vacuum pump operating hours Scale adjustment data for fresh oil and used oil Fresh oil scales adjustment date Used oil scales adjustment date 14 7...

Page 36: ...aborted and the message FILLING IN COMPLETE appears on the display 20 T14 EV9 UV contrast medium open duration Time in seconds for which the solenoid valve EV9 is open Corresponds to the time for which UV contrast medium is added 2 T15 Maximum time for the oil filling process If this time is exceeded the function is aborted and the message HIGH OIL FILL ING TIME appears on the display 10 T16 Maxim...

Page 37: ...ush simultaneously and release The message ENTER CODE 0000 is displayed 3 Enter 5599 and confirm with E 4 Select BACKUP with o u and confirm with E INSERT THE KEY is displayed 5 Remove plastic cover input PS2 stick between menu key and stop key Do not use the PS2 stick with the new software ver sion as the stick is cleared before the data backup 6 Insert PS2 stick 7 Confirm that any data on the st...

Page 38: ...1 689 975 252 2019 05 15 Robert Bosch GmbH 38 ACS 511 Circuit diagram en 17 Circuit diagram 17 1 Control PCB Fig 6 Control PCB Fig 7 Control PCB ...

Page 39: ...IL IN OIL PRN TANK CPU 1 1 2 3 4 5 6 7 8 9 Fig 8 Computer printed circuit board 1 Internal refrigerant scales connection 2 Power supply printer connection 3 Fresh oil scales connection 4 Used oil scales connection 5 Pressure sensor connection 6 Internal printer connection 7 Programming connection 8 Not used 9 Control PCB connection supply PCB ...

Page 40: ...Robert Bosch GmbH Franz Oechsle Straße 4 73207 Plochingen DEUTSCHLAND www bosch com bosch prueftechnik bosch com 1 689 975 252 2019 05 15 ...

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