Bosch ACS 511 Repair Instruction
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Bosch ACS 511 Repair Instruction

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ACS 511
en Repair instruction
A/C Service Unit

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Summary of Contents for Bosch ACS 511

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

  • Page 2: Table Of Contents

    2 | ACS 511 | en – Contents Troubleshooting Service messages Symbols used Fault messages In the documentation 1.1.1 Warning notices - Emptying the ACS 511 Structure and meaning 10.1 Automatic emptying 1.1.2 Symbols in this documentation 10.2 Extraction of internal refrigerant circuit with sec-...

  • Page 3: Symbols Used

    Symbols used | ACS 511 | 3 Symbols used Component test 14.1 LCD In the documentation 14.2 Outputs 14.3 Control PCB input signal 1.1.1 Warning notices - 14.4 Printer Structure and meaning 14.5 Counter Warning notices warn of dangers to the user or people 14.6 Service printout...

  • Page 4: Important Information

    4 | ACS 511 | Important information Important information Test equipment and auxil- iary materials Installation and/or repairs must only be performed by trained and instructed Bosch customer service rep- resentatives or companies authorized by Bosch If the General tools for electricians and A/C mechanics units are opened or modified by unauthorized persons, Digital multimeter (e.g.

  • Page 5: Safety Regulations

    Before connecting the ACS 511 to a vehicle air con- ble transmission of current through the body. ditioning system or an external refrigerant cylinder,...

  • Page 6: Notes On Operation

    Never Parameters Specification leave the ACS 511 unattended when in operation. Position the ACS 511 on all four wheels on a flat, Rated voltage 230 VAC ± 10 % vibration-proof surface such that proper operation of...

  • Page 7: Product Description

    Product description | ACS 511 | 7 Product description 5.1.2 Rear view Description of unit 5.1.1 Front view Fig. 2: Rear view Fig. 1: Front view 1 Service quick-release coupling (low pressure) 2 Service quick-release coupling (high pressure) 1 High pressure valve...

  • Page 8: Display And Control Panel

    Terminate and return. For updating firmware/software or database Various functions are assigned to the <MENU> function key in the ACS 511 software. The functions of the keys are defined in the menu line of the ACS 511 software. 5.1.5 Input keys The input keys can be used to enter letters, numbers and special characters in the input boxes.

  • Page 9: Program Structure

    Program structure | ACS 511 | 9 Program structure Manual mode Input Menu Calibration and tare SELECT PORTS Input Menu TANK CALIBRATION <RECOVERY> R Automatic emptying IN OIL CALIBRATION + < > 1111 R Extraction 2. Enter OUT OIL CALIBRATION R Oil drain 3.

  • Page 10: Hydraulics Diagram

    10 | ACS 511 | Hydraulics diagram Hydraulics diagram HIGH EV10 Name Description Name Description Name Description Fresh oil tank Recovery solenoid valve Pressure sensor Vacuum pump Filling solenoid valve Pressure switch Low pressure hose Expansion valve Oil drain solenoid valve...

  • Page 11: Service Phases

    1. The ACS 511 is connected to the vehicle with the At the end of this phase, the solenoid valves EV10, EV3 service hoses T1 and T2.
  • Page 12 12 | ACS 511 | Service phases HIGH EV10 active Name Description Name Description Name Description Pressure sensor Fresh oil tank Recovery solenoid valve Vacuum pump Filling solenoid valve Pressure switch Expansion valve Oil drain solenoid valve Low pressure hose...

  • Page 13: Draining Oil Into The Used Oil Bottle

    The used oil bottle scales (13) weigh the drained used At the end of recovery, the solenoid valve EV7 opens oil and ACS 511 saves the value for fresh oil filling in and the oil previously separated out in the evaporator/ automatic mode.

  • Page 14: Vacuum Phase And Recycling (Simultaneous)

    6. ant. In that way, refrigerant is sucked from storage bottle 1. The ACS 511 is connected to the vehicle with the 7 and is conveyed through the filter F1, the expan- service hoses T1 and T2.
  • Page 15 Service phases | ACS 511 | 15 HIGH EV10 active Name Description Name Description Name Description Pressure sensor Fresh oil tank Recovery solenoid valve Vacuum pump Filling solenoid valve Pressure switch Expansion valve Oil drain solenoid valve Low pressure hose...

  • Page 16: Leak Test

    16 | ACS 511 | Service phases Leak test If the pressure at P 1 falls below the value saved in the software during the leak test, an error message The leak test starts after the vacuum phase. is displayed.

  • Page 17: Refrigerant Preparation

    Service phases | ACS 511 | 17 Refrigerant preparation Internal preparation of the refrigerant is the same process that the ACS 511 performs in the recovery 1. Press the <MENU> key. phase to clean the refrigerant recovered from the 2. Select <R134a PREPARATION> and confirm with E.

  • Page 18: Fresh Oil Filling

    18 | ACS 511 | Service phases Fresh oil filling If "Fresh oil filling" has been selected in the service process, the quantity of fresh oil entered is fed into By default, individual service phases are linked to the vehicle air conditioning system along with the other service phases as they are needed to fully per- refrigerant.

  • Page 19: Uv Contrast Medium Filling

    Service phases | ACS 511 | 19 UV contrast medium filling If "UV contrast medium filling" has been selected in the service process, a defined quantity (time con- By default, individual service phases are linked to trolled) entered is fed into the vehicle air condition- other service phases as they are needed to fully per- ing system along with the refrigerant.

  • Page 20: Filling Refrigerant

    20 | ACS 511 | Service phases Filling refrigerant Open EV3 and EV6. Refrigerant flows from the internal refrigerant cylin- The refrigerant in the internal refrigerant cylinder is der through valves V4 and V2, through the solenoid used for filling the vehicle air conditioning system.

  • Page 21: Separating And Returning Compressor Oil

    Service phases | ACS 511 | 21 Separating and returning compressor This oil is separated from the refrigerant in the com- pressor oil separator (5) and is then fed back to the compressor (6). During the recovery phase and preparation of the refrigerant, small quantities of compressor oil get into the internal circuit.

  • Page 22: Non-Condensing Gases

    22 | ACS 511 | Service phases 8.10 Non-condensing gases The pressure of the internal refrigerant cylinder in- creases during the recovery phase and when prepar- The drain valve (V6) for non-condensing gases opens ing the refrigerant. if the pressure in the refrigerant cylinder is higher...

  • Page 23: Troubleshooting

    Actions HIGH PRESSURE There is excess pressure at the outlet of the compressor. Turn off the ACS 511 and wait approx. 30 minutes. PROGRAM ERROR Error in the software. FULL TANK The internal refrigerant cylinder has been filled to maximum filling level. Carry out several refill procedures to reduce the internal refrigerant quantity.

  • Page 24: Emptying The Acs 511

    2. Close service quick-release couplings. cylinder. " 3. Open HP and LP valves on the ACS 511. Repairs can be performed. 4. Start recovery. " Automatic emptying is performed. 1 689 975 252...

  • Page 25: Troubleshooting And Analysis

    2,5 and 2,7 bar. Before carrying out any service intervention, re- 5. Check compressor (6). duce the ACS 511 pressure so that no refrigerant is released. ACS 511 ends the recovery phase but the pressure at the pressure gages does not change.

  • Page 26: Fault Messages That Can Occur During Recovery

    26 | ACS 511 | TROUBLESHOOTING AND ANALYSIS 11.2 Faults during the vacuum phase 11.1.3 Fault messages that can occur during recovery 11.2.1 The vacuum pump starts "CYLINDER FULL" The vacuum pump starts but no vacuum is generated Check the weight of the internal refrigerant cylinder...

  • Page 27: Fault Message That Can Occur During The Vacuum Phase

    TROUBLESHOOTING AND ANALYSIS | ACS 511 | 27 11.5 Faults during filling with refrigerant 11.2.3 Fault message that can occur during the vacu- um phase 11.5.1 Vehicle air conditioning system cannot be "A/C SYSTEM FULL" filled 1. Check hose connections on the internal refrigerant ¶...

  • Page 28: Component Test And Maintenance

    28 | ACS 511 | Component test and maintenance 12. Component test and main- 12.3 Pressure switch P2 tenance The pressure switch is normally closed between contacts 1 and 2, and open between contacts 1 and 12.1 Vacuum pump 4. The pressure switch opens at 16 bar.

  • Page 29: Combo Filter

    Component test and maintenance | ACS 511 | 29 12.5 Combo filter 4. Close the HP and LP valves on the display and 12.5.1 Replacement of combo filter control panel. 5. Switch off ACS 511. DANGER – Risk of electric shock from 6.

  • Page 30: Vacuum Pump

    30 | ACS 511 | Component test and maintenance 12.6 Vacuum pump 1. Place a vessel under the drain. 12.6.1 Changing vacuum pump oil 2. Remove drain plug and oil fill plug from vacuum pump. DANGER – Risk of electric shock from 3.

  • Page 31: 13. Calibration

    Calibration | ACS 511 | 31 13. Calibration 13.2 Fresh oil bottle scales 13.1 Internal refrigerant cylinder scales According to the display, the calibration weight must be entered in ml. However, we recommend enter- Detach the rear panel and remove the refrigerant ing the weight in grams.

  • Page 32: Tara Values

    32 | ACS 511 | Calibration 13.3 Used oil bottle scales 13.4 Tara values The following Tara values for the Internal refrigerant According to the display, the calibration weight must cylinder and oil bottles are set from the factory. be entered in ml. However, we recommend enter- ing the weight in grams.

  • Page 33: Pressure Sensor

    5 minutes (this subjects the pres- 5. Remove the service hoses on the ACS 511 and open sure sensor to a vacuum). the HP and LP valves on the front panel so that the 4.
  • Page 34 34 | ACS 511 | Component test 14. Component test 14.3 Control PCB input signal 14.1 Follow the additional ACS 511 menu prompting. Follow the additional ACS 511 menu prompting. 1. Call up the start screen. 2. Press <3> and <Flush> simultaneously and release.
  • Page 35 EV7 to be serviced. This function displays the total number of operations Follow the additional ACS 511 menu prompting. performed with the ACS 511 since initial commis- sioning. 1. Call up the start screen. 2. Press <3> and <Flush> simultaneously and release.
  • Page 36 1. Call up the start screen. 2. Press <3> and <Flush> simultaneously and release.  The message ENTER CODE 0000 The set values guarantee that the ACS 511 will is displayed. 5599 and confirm with E . function perfectly. These parameters may only be 3.
  • Page 37 3. Press and hold the <MENU> key.  INSERT THE KEY is displayed. 4. Turn on the ACS 511 and release the <MENU> key. 5. Remove plastic cover (input PS2 stick) between 5. The ACS 511 turns itself off after programming. menu key and stop key.
  • Page 38 38 | ACS 511 | Circuit diagram 17. Circuit diagram 17.1 Control PCB Fig. 6: Control PCB Fig. 7: Control PCB 1 689 975 252 2019-05-15 Robert Bosch GmbH...
  • Page 39 Circuit diagram | ACS 511 | 39 17.2 Computer printed circuit board 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...
  • 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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