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Bosch ACS 652, Repair Instruction

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Bosch ACS 652 Repair Instruction Download Page 39

1 689 975 257

2019-05-15

| 

Robert Bosch GmbH

 Circuit diagram  |  ACS 652  |  39

en

17.2  Computer printed circuit board

CP

U

PROGRA

M

RS-232

PRESSURE

OUT OI

L

IN OI

L

PR
N

TANK

CPU-

1

1

2

3

4

5

6

7

8

9

Fig. 7: 

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  Control PCB connection
9  Control PCB connection (supply PCB)

Summary of Contents for ACS 652

Page 1: ...ACS 652 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 652 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: ...e action and information given Hazard prevention action and information The key word indicates the likelihood of occurrence and the severity of the hazard in the event of non obser vance Key word Probability of occurrence Severity of danger if in structions not observed DANGER Immediate impend ing danger Death or severe injury WARN ING Possible impending danger Death or severe injury CAUTION Possi...

Page 4: ...he 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 Tes...

Page 5: ...hich 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 refrigerants can damage the vehicle air conditioning system 4 2 Handling UV dye Never inh...

Page 6: ...course of maintenance work R R We recommend calibrating the internal refrigerant 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 tri...

Page 7: ...bottle PAG or POE 7 UV dye bottle 8 Used oil bottle 9 Cover 10 Front wheels with locking brake i i The high 4 and low pressure 3 gages show the current pressure during the air conditioning service on the vehicle The small gage 5 is used to check the bottle pressure in the internal refrigerant cylinder 5 1 2 Rear view 1 5 4 3 2 6 7 Fig 2 Rear view 1 Service quick release coupling low pressure 2 Ser...

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: ...Description 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 EVHP1 High pressure solenoid valve EVHP2 High pressure solenoid valve EVLP1 Low pressure solenoid valve EVLP2 Low pressure solenoid valve F1 Coarse filter F2 Combi filter HP High pressure LP LOw pressure M1 Low pressure gag...

Page 11: ...rts extraction of the refrigerant The solenoid valves EV10 EV3 and EV5 are opened and the compressor 6 is started R R The refrigerant flows through the solenoid valves EVLP1 EVLP2 EVHP1 EVHP2 EV10 EV3 and EV5 the mechanical filter F1 the expansion valve 3 and the condenser separator 4 R R The expansion valve 3 maintains a constant pres sure at the evaporator oil separator 4 R R In the evaporator o...

Page 12: ...V7 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 EVHP1 High pressure solenoid valve EVHP2 High pressure solenoid valve EVLP1 Low pressure solenoid valve EVLP2 Low pressure solenoid valve F1 Coarse filter F2 Combi filter HP High pressure LP LOw pressure M1 Low pressure gage M2 High pre...

Page 13: ...12 Fresh oil scales 13 Used oil scales EV1 Vacuum solenoid valve EV3 Flow solenoid valve EV5 Recovery solenoid valve EV6 Filling solenoid valve Name Description 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 EVHP1 High pressure solenoid valve EVHP2 High pressure solenoid valve EVLP...

Page 14: ... below the set value the vehicle air conditioning system is empty and the ACS 652 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 mb...

Page 15: ...V7 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 EVHP1 High pressure solenoid valve EVHP2 High pressure solenoid valve EVLP1 Low pressure solenoid valve EVLP2 Low pressure solenoid valve F1 Coarse filter F2 Combi filter HP High pressure LP LOw pressure M1 Low pressure gage M2 High pre...

Page 16: ... UV dye bottle 12 Fresh oil scales 13 Used oil scales EV1 Vacuum solenoid valve EV3 Flow solenoid valve EV5 Recovery solenoid valve EV6 Filling solenoid valve Name Description 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 EVHP1 High pressure solenoid valve EVHP2 High pressure sole...

Page 17: ... Heat exchanger 11 UV dye bottle 12 Fresh oil scales 13 Used oil scales EV1 Vacuum solenoid valve EV3 Flow solenoid valve EV5 Recovery solenoid valve EV6 Filling solenoid valve Name Description 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 EVHP1 High pressure solenoid valve EVHP2 ...

Page 18: ...lve 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 EV5 Recovery solenoid valve EV6 Filling solenoid valve Name Description EV7 Oil drain solenoid valve EV8 Oil injection soleno...

Page 19: ...aporator 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 EV5 Recovery solenoid valve EV6 Filling solenoid valve Name Description EV7 Oil drain solenoid valve EV8 Oil injection solenoid valve...

Page 20: ...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 EV5 Recovery solenoid valve EV6 Filling solenoid valve Name Description EV7 Oil drain solenoid valve EV8 Oil injection solenoid valve EV9 Contrast medium injection sole noid...

Page 21: ...scales 13 Used oil scales EV1 Vacuum solenoid valve EV3 Flow solenoid valve EV5 Recovery solenoid valve EV6 Filling solenoid valve Name Description 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 EVHP1 High pressure solenoid valve EVHP2 High pressure solenoid valve EVLP1 Low pressur...

Page 22: ...der 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 EV5 Recovery solenoid valve EV6 Filling solenoid valve Name Description 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 EVHP1 High...

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: ...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 compressor power supply for...

Page 25: ...wer 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 pressure...

Page 26: ...n the vehicle air conditioning system 1 Disconnect service hoses from vehicle 2 Check whether the hose connected to the vacuum pump is correctly connected at both ends and is not clogged 3 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 4 Check the pump vacuum output the pressure must fall to less than 0 05 mbar w...

Page 27: ...rigerant circuit 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 can...

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 14 5 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 valv...

Page 29: ...curing the new filter Pay attention to correct positioning of the 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 652 menu prompting 1 Call up start screen 2 Press Recovery ACS 652 performs a self cleaning process then the recovery phase i i Pressure gauge must reach 0 bar 3 Swi...

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: ... value 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 ...

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 refri...

Page 33: ...eter on 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 pressu...

Page 34: ...mpressor 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 EVHP1 EVHP2 EVLP1 EVLP2 EV11 EVFLU not used i i Return with Stop 14 3 Control PCB input s...

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: ...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 Maximum time for ...

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: ...11 RL5 RL6 RL7 RL8 RL9 C1 C2 C3 C5 C6 C7 C8 C9 C10 RL10 VR1 VR2 VR3 VR4 VR5 VR6 VR7 VR8 VR9 VR10 F2 CN4 CN5 F3 F1 CN6 CN7 RL4 RL3 C14 RL12 VR12 CN20 C15 RL13 VR13 CN21 CN22 C16 RL14 VR14 CN23 CN24 CN8 CN9 CN2 CN10 CN11 CN12 CN13 CN14 CN15 CN16 CN17 CN18 T N L T N L EV3 2 P 6 C P2 10 N 230 V INT IN FAN 1 COMP HP FAN 2 PUMP EV1 EV2 EV3 EV4 EV1 EV8 EV10 EV9 EV7 EV6 EV5 EV5 EV6 EV7 EV8 EV9 EV10 EVHP1 ...

Page 39: ...IL PRN TANK CPU 1 1 2 3 4 5 6 7 8 9 Fig 7 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 Control PCB connection 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 1 689 975 257 2019 05 15 ...

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