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Bosch ACS 810, Repair Instructions

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Bosch ACS 810 Repair Instructions Download Page 21

Service phases | ACS 810 | 21 |

en

1 689 975 253

2021-01-26

| 

Robert Bosch GmbH

8.9 

Non-condensing gases

 

i

The drain valve (V6) for non-condensing gases 
opens if the pressure in the refrigerant cylinder 
is higher than the set opening pressure (normally 
between 12 and 14 bar).

 

i

The pressure of the internal refrigerant cylinder 
increases during the recovery phase and when 
preparing the refrigerant.

 

i

The safety valve (V5) opens at a factory set 
pressure (approx. 18 bar) to limit the pressure in 
the internal refrigerant cylinder.

Des. 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 scale

9

Used oil bottle

10

Heat exchanger

11

Refrigerant pump

T1

Low pressure hose

T2

High pressure hose

M1

Low pressure gage

M2

High pressure gage

M3

Internal refrigerant cylinder pressure gage

F1

Coarse filter

Des. Description

F2

Combi filter

VU1

Oil non-return valve

EV1

Vacuum solenoid valve

EV3

Flow solenoid valve

EV5

Recovery solenoid valve

EV6

Filling solenoid valve

EV7

Oil drain solenoid valve

EV8

Oil injection solenoid valve

EV10 Refrigerant pump by-pass solenoid valve
P1

Pressure sensor

P2

Pressure switch

V1

Tank vapour side hose valve

V2

Tank liquid side hose valve

V3

Tank vapour side valve

V4

Tank liquid side valve

V5

Safety valve

V6

Non condensable drain valve

M2

HIGH

LOW

P1

T1

T2

EV8

1

2

P

EV1

EV5

EV3

EV6

3

F1

C

P2

HP

5

6

F2

9

4

EV7

10

7

V1

8

V3

V2

V4

V6

V5

M1

M3

EV10

VU1

11

P

Summary of Contents for ACS 810

Page 1: ...ACS 810 A C service unit en Repair instructions A C service unit ...

Page 2: ... 8 Separating and returning compressor oil 20 8 9 Non condensing gases 21 9 Troubleshooting 22 9 1 Service messages 22 9 2 Fault messages 22 10 Emptying the ACS 810 23 10 1 Automatic emptying 23 10 2 Extraction of internal refrigerant circuit with second A C service unit 23 11 TROUBLESHOOTING AND ANALYSIS 24 11 1 Faults during recovery 24 11 1 1 Compressor starts 24 11 1 2 Compressor does not star...

Page 3: ...ol 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 intermediate result Final result There is a visible final result on completion of the instru...

Page 4: ...itial testing it is ensured that the 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 dire...

Page 5: ...ammable Such mixtures are a potential hazard and may lead to fire or explosions and thus cause damage or injury R Refrigerant extracted from a vehicle air conditioning system may be contaminated with moisture lubricant dirt and traces of other gases R R134a is not to be used in areas in which there is a danger of explosion Fire naked flames and smoking are prohibited Welding and soldering are not ...

Page 6: ...course of maintenance work R We recommend calibrating the internal refrigerant scales at least once per year Please contact customer service 4 5 Safety devices For safety reasons it is advisable to use a residual current operated circuit breaker rccb with the following specifications Parameters Specification Rated voltage 230 VAC 10 Rated frequency 50 Hz Rated current 230 VAC 10 A Rated tripping c...

Page 7: ...er 8 Fresh oil bottle 9 Used oil bottle 10 Front wheels with locking brake 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 The two valve settings are labeled as follows C Close valve is closed O Open valve is open 5 1 2 Rear view 4 1 2 3 4 ...

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

Page 9: ...nd 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 1 REPORT MANAGEMENT PRINT REPORT EXPORT DATA DELETE DATA 6 6 Manual mode Input Menu RECOVERY R Automatic emptying R Extraction R Oil drain R Pressure ...

Page 10: ...anger 11 Refrigerant pump T1 Low pressure hose T2 High pressure hose M1 Low pressure gage M2 High pressure gage M3 Internal refrigerant cylinder pressure gage F1 Coarse filter Des Description F2 Combi filter VU1 Oil non return valve EV1 Vacuum solenoid valve EV3 Flow solenoid valve EV5 Recovery solenoid valve EV6 Filling solenoid valve EV7 Oil drain solenoid valve EV8 Oil injection solenoid valve ...

Page 11: ...rigerant The solenoid valves EV10 EV3 and EV5 are opened and the compressor 6 is started 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 The expansion valve maintains a constant pressure at the evaporator oil separator 4 R In the evaporator oil separator 4 the oil extracted from the vehicle air con...

Page 12: ...nt cylinder pressure gage F1 Coarse filter Des Description F2 Combi filter VU1 Oil non return valve EV1 Vacuum solenoid valve EV3 Flow solenoid valve EV5 Recovery solenoid valve EV6 Filling solenoid valve EV7 Oil drain solenoid valve EV8 Oil injection solenoid valve EV10 Refrigerant pump by pass solenoid valve P1 Pressure sensor P2 Pressure switch V1 Tank vapour side hose valve V2 Tank liquid side...

Page 13: ...ressure hose T2 High pressure hose M1 Low pressure gage M2 High pressure gage M3 Internal refrigerant cylinder pressure gage F1 Coarse filter Des Description F2 Combi filter VU1 Oil non return valve EV1 Vacuum solenoid valve EV3 Flow solenoid valve EV5 Recovery solenoid valve EV6 Filling solenoid valve EV7 Oil drain solenoid valve EV8 Oil injection solenoid valve EV10 Refrigerant pump by pass sole...

Page 14: ...o the pressure sensor P1 solenoid valves EV1 EV3 and EV10 are closed P1 checks the pressure in the vehicle air conditioning system refrigerant present in the vehicle air conditioning system or not i If the pressure in the vehicle air conditioning system is below the set value the vehicle air conditioning system is empty and the ACS 810 starts vacuum generation i If the pressure is above the set va...

Page 15: ...nt cylinder pressure gage F1 Coarse filter Des Description F2 Combi filter VU1 Oil non return valve EV1 Vacuum solenoid valve EV3 Flow solenoid valve EV5 Recovery solenoid valve EV6 Filling solenoid valve EV7 Oil drain solenoid valve EV8 Oil injection solenoid valve EV10 Refrigerant pump by pass solenoid valve P1 Pressure sensor P2 Pressure switch V1 Tank vapour side hose valve V2 Tank liquid side...

Page 16: ...e 9 Used oil bottle 10 Heat exchanger 11 Refrigerant pump T1 Low pressure hose T2 High pressure hose M1 Low pressure gage M2 High pressure gage M3 Internal refrigerant cylinder pressure gage F1 Coarse filter Des Description F2 Combi filter VU1 Oil non return valve EV1 Vacuum solenoid valve EV3 Flow solenoid valve EV5 Recovery solenoid valve EV6 Filling solenoid valve EV7 Oil drain solenoid valve E...

Page 17: ... Vacuum pump 3 Expansion valve 4 Evaporator oil separator 5 Compressor oil separator 6 Compressor 7 Internal refrigerant cylinder 8 Refrigerant cylinder scale 9 Used oil bottle 10 Heat exchanger 11 Refrigerant pump T1 Low pressure hose T2 High pressure hose M1 Low pressure gage M2 High pressure gage M3 Internal refrigerant cylinder pressure gage F1 Coarse filter Des Description F2 Combi filter VU1...

Page 18: ...off the refrigerant pump 11 Des 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 scale 9 Used oil bottle 10 Heat exchanger 11 Refrigerant pump T1 Low pressure hose T2 High pressure hose M1 Low pressure gage M2 High pressure gage M3 Internal refrigerant cylinder pres...

Page 19: ...service process Des 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 scale 9 Used oil bottle 10 Heat exchanger 11 Refrigerant pump T1 Low pressure hose T2 High pressure hose M1 Low pressure gage M2 High pressure gage M3 Internal refrigerant cylinder pressure gage F1...

Page 20: ... 10 Heat exchanger 11 Refrigerant pump T1 Low pressure hose T2 High pressure hose M1 Low pressure gage M2 High pressure gage M3 Internal refrigerant cylinder pressure gage F1 Coarse filter Des Description F2 Combi filter VU1 Oil non return valve EV1 Vacuum solenoid valve EV3 Flow solenoid valve EV5 Recovery solenoid valve EV6 Filling solenoid valve EV7 Oil drain solenoid valve EV8 Oil injection so...

Page 21: ...nternal refrigerant cylinder 8 Refrigerant cylinder scale 9 Used oil bottle 10 Heat exchanger 11 Refrigerant pump T1 Low pressure hose T2 High pressure hose M1 Low pressure gage M2 High pressure gage M3 Internal refrigerant cylinder pressure gage F1 Coarse filter Des Description F2 Combi filter VU1 Oil non return valve EV1 Vacuum solenoid valve EV3 Flow solenoid valve EV5 Recovery solenoid valve E...

Page 22: ...LL TANK The internal refrigerant cylinder has been filled to maximum filling level Carry out several refill procedures to reduce the internal refrigerant quantity HIGH RECOVERY TIME The recovery time exceeds the set maximum duration Check the vehicle air conditioning system for leaks If error persists contact customer service A C SYSTEM EMPTY There is no refrigerant in the vehicle air conditioning...

Page 23: ... Automatic emptying is performed 10 2 Extraction of internal refrigerant circuit with second A C service unit 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 The compressor p...

Page 24: ...d with power 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 F1 If clogged clean with compressed air blow out 2 Valves V1 and V3 must be open 3 Check expansion valve 3 with a pressure gage Operating pressure must be between ...

Page 25: ... 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 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 0 033 mbar within 3 minute...

Page 26: ...t drain valve V6 11 5 Faults during filling with refrigerant 11 5 1 Vehicle air conditioning system cannot be filled If the refrigerant pump works but does not charge the A C system it is necessary to 1 Check hose connections on the internal refrigerant cylinder 2 Valves V1 V2 V3 and V4 must be open 3 HP and LP valves must be open 4 Check the calibration of the scale i Ensure that the refrigerant ...

Page 27: ... 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 on the refrigerant cylinder 4 Remove the blue hose from the internal refrigerant cylinder and connect a pressure gage using a T piece 5 Open V4 6 Open V1 7 Sta...

Page 28: ...o filter 12 6 1 Replacement of combo filter DANGER Risk of electric shock from dangerous voltage Electric shocks resulting from contact with live parts e g master switch printed circuit boards can cause injury heart failure and death Disconnect the mains plug before opening the ACS 810 WARNING Risk of frostbite from escaping refrigerant Refrigerant causes severe frostbite on the skin Check the ser...

Page 29: ...orrect positioning of the sealing rings Fig 5 Combo filter 10 Close the housing The filter is replaced i Return with Stop 12 6 2 Reset filter Observe the ACS 810 menu prompting 1 Call up start screen 2 Press 3 and Flush simultaneously and release The message ENTER CODE 0000 is displayed 3 Enter code 5555 and confirm with E 4 Select CHANGE FILTER with o u and confirm with E The current quantity in ...

Page 30: ...cified by Bosch 1 3 2 Fig 6 Vacuum pump 1 Sight class 2 Oil fill plug 3 Drain plug Do not use excessive force when securing and removing the oil drain and oil filling screw 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 in ...

Page 31: ...nfirm with E The display shows WEIGHT CALIBRATION 6 Place the calibration weight on the weighing tray a value of between 10 kg and 20 kg is recommended 7 Enter the calibration weight value and confirm with E The menu containing the functions appears on the display again i Return with Stop 13 2 Tara values The following Tara values for the Internal refrigerant cylinder is set from the factory Inter...

Page 32: ...0 is displayed 3 Enter 1515 and confirm with E 4 Select INPUTS TEST with o u and confirm with E The absolute values of the scales and of the pressure sensor is displayed 5 Remove the service hoses on the ACS 810 and open the HP and LP valves on the front panel so that the pressure sensor is subjected to the atmospheric pressure 6 Check that the pressure value read is between 0 900 and 1 100 bar th...

Page 33: ...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 refrigerant pump Solenoid valve EV10 by pass solenoid valve for refrigerant pump i Return with Stop 14 3 Control PCB input si...

Page 34: ...e The message ENTER CODE 0000 is displayed 3 Enter 1515 and confirm with E 4 Select SERVICE PRINTING with o u and confirm with E i Return with Stop The following data appears in the service print out Total quantity of refrigerant recovered Vacuum pump operating hours Scale adjustment date for internal refrigerant cylinder Fresh oil scale adjustment date not used Used oil scale adjustment date not ...

Page 35: ...executed 300 T10 Recycling plus vacuum time Time in minutes for the duration of the recycling plus vacuum function 10000 T13 Maximum time for the filling process If this time is exceeded the function is aborted and the message FILLING INCOMPLETE appears on the display 50 Parameter Actions Default T16 Maximum time for the flushing process If this time is exceeded the function is ended and the proce...

Page 36: ...sh 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 version as the stick is cleared before the data backup 6 Insert PS2 stick 7 Confirm that any data on the stic...

Page 37: ...Circuit diagram ACS 810 37 en 1 689 975 253 2021 01 26 Robert Bosch GmbH 17 Circuit diagram 17 1 Control PCB Fig 7 Control PCB Fig 8 Control PCB ...

Page 38: ... 232 PRESSURE OUT OIL IN OIL PRN TANK CPU 1 1 2 3 4 5 6 7 8 9 Fig 9 Computer printed circuit board 1 Internal refrigerant scale connection 2 Printer power supply connection 3 Not used 4 Not used 5 Pressure sensor connection 6 Internal printer connection 7 Programming connection 8 Not used 9 Control PCB connection supply PCB ...

Page 39: ......

Page 40: ... downloads bosch automotive com www boschaftermarket com Robert Bosch GmbH Automotive Service Solutions Franz Oechsle Straße 4 73207 Plochingen DEUTSCHLAND bosch prueftechnik bosch com 1 689 975 253 2021 01 26 ...

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