ACS 810

A/C service unit

en Repair instructions A/C service unit

en | 2 | ACS 810 | 
en – Contents
1. Symbols used 3
1.1 In the documentation 3
1.1.1 Warning notices - Structure and
meaning 3
1.1.2 Symbols in this documentation 3
1.2 On the product 3
2. Important information 4
3. Test equipment and auxiliary materials 4
4. Safety regulations 5
4.1 Handling refrigerant R134a 5
4.2 Working on the vehicle 5
4.3 Notes on operation 6
4.4 Maintenance work 6
4.5 Safety devices 6
4.6 PED directive 2014/68/EU 6
5. Product description 7
5.1 Description of unit 7
5.1.1 Front view 7
5.1.2 Rear view 7
5.1.3 Display and control panel 8
5.1.4 Selection and function keys 8
5.1.5 Input keys 8
6. Program structure 9
6.1 Calibration and tare 9
6.2 Settings 9
6.3 Repair 9
6.4 Vehicle and customer data 9
6.5 Menu 9
6.6 Manual mode 9
6.7 Automatic mode 9
6.8 Flush (optional) 9
6.9 Enter 9
7. Hydraulics diagram 10
8. Service phases 11
8.1 Recovery 11
8.2 Draining oil into the used oil bottle 13
8.3 Vacuum phase 14
8.4 Leak test 16
8.5 Refrigerant preparation 17
8.6 Fresh oil filling 18
8.7 Filling refrigerant 19
8.8 Separating and returning compressor oil 20
8.9 Non-condensing gases 21
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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 start 24
11.1.3 Fault messages that can occur during
recovery 25
11.1.4 Other fault messages 25
11.2 Faults during the vacuum phase 25
11.2.1 The vacuum pump starts 25
11.2.2 The vacuum pump does not start 25
11.2.3 Fault message that can occur during the
vacuum phase 26
11.3 Faults during refrigerant preparation 26
11.4 Non-condensing gases are not drained 26
11.5 Faults during filling with refrigerant 26
11.5.1 Vehicle air conditioning system cannot
be filled 26
11.5.2 Other fault messages 26
12. Component test and maintenance 27
12.1 Vacuum pump 27
12.2 Pressure sensor P1 27
12.3 Pressure switch P2 27
12.4 Expansion valve 27
12.5 Periodic check of the non-condensable gas
purge valve 28
12.6 Combo filter 28
12.6.1 Replacement of combo filter 28
12.6.2 Reset filter 29
12.7 Vacuum pump 30
12.7.1 Changing vacuum pump oil 30
12.7.2 Reset of oil change interval 30
Robert Bosch GmbH
 Symbols used | ACS 810 | 3 | en

13. Calibration 31 1. Symbols used

13.1 Internal refrigerant cylinder scale 31
13.2 Tara values 31
13.3 Pressure sensor 32
13.3.1 Checking the adjustment 32
13.3.2 Adjusting the pressure sensor 32
14. Component test 33
14.1 LCD 33
14.2 Outputs 33
14.3 Control PCB input signal 33
14.4 Printer 33
14.5 Counter 34
14.6 Service printout 34
14.7 Draining oil 34
1.1 In the documentation
1.1.1 Warning notices - Structure and meaning
Warning notices warn of dangers to the user or
people in the vicinity. Warning notices also indicate
the consequences of the hazard as well as preventive
action. Warning notices have the following structure:
KEY WORD – Nature and source of hazard!
Warning
symbol Consequences of hazard in the event of
failure to observe action and information
given.
¶ Hazard prevention action and
information.

15. Changing basic settings 35 The key word indicates the likelihood of occurrence
and the severity of the hazard in the event of non-
16. Software 36 observance:
16.1 Vehicle database 36
16.2 Data backup 36 Key word Probability of Severity of danger if
occurrence instructions not observed
16.3 Software update 36
16.4 Loading a data backup 36 DANGER Immediate Death or severe injury
impending danger
WARNING Possible impending Death or severe injury
17. Circuit diagram 37 danger
17.1 Control PCB 37 CAUTION Possible dangerous Minor injury
17.2 Computer printed circuit board 38 situation

1.1.2 Symbols in this documentation

Symbol Designation Explanation

Attention Warns about possible property
! damage.
Information Practical hints and other
i
useful information.
1. Multi-step Instruction consisting of several
2. operation steps.
One-step Instruction consisting of one step.
e
operation
Intermediate An instruction produces a visible

result intermediate result.
Final result There is a visible final result on
"
completion of the instruction.

1.2 On the product

! Observe all warning notices on products and

ensure they remain legible.

¶ Wear safety goggles.

¶ Wear protective gloves.

¶ Protect against dampness and moisture.

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en | 4 | ACS 810 | Important information

2. Important information 3. Test equipment and

auxiliary materials
Installation and/or repairs must only be performed
by trained and instructed Bosch customer service
representatives or companies authorized by Bosch R General tools for electricians and A/C mechanics
If the units are opened or modified by unauthorized R Digital multimeter (e.g. MMD 003)
persons, any warranty claims become void. R Loctite 542 (for thread seal) and 222 (for thread
lock)
Electrical systems and devices must only be put into R Cleaning agent (e.g. brake cleaner)
operation when in proper operating condition (details R Calibrating weight 10 - 20 kg for internal refrigerant
can be found in the EDIS-Info 200108_084). This scale
requirement is met if following modification or repair R Leak detector (1 689 100 057)
(initial testing) it is ensured that the requirements R Simulator (optional)
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.

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4. Safety regulations
! Always carefully read and observe all the safety
regulations before using the Bosch product.
¶ Wear safety goggles.
¶ Wear safety gloves.
4.1 Handling refrigerant R134a
Avoid all skin contact with the refrigerant.
The low boiling point of the refrigerant
(approx. -30 °C) can lead to frostbites.
Should it nevertheless come into contact
with the skin, remove any moistened
clothing immediately and rinse the affected
skin with copious amounts of water.
R R134a is colorless, has a weak intrinsic odor and is
heavier than air. It displaces oxygen and may flow into
repair pits. Should refrigerant escape (malfunction),
always ensure adequate ventilation and air extraction
(especially in pits). Exit the workshop.
Never inhale refrigerant and oil vapors.
The vapors can irritate the eyes, nose and
respiratory system. If liquid refrigerant
comes into contact with the eyes, rinse them
thoroughly with water for 15 minutes. Then
obtain medical help even if no pain is felt.
R Before connecting the ACS 810 to a vehicle air
conditioning system or an external refrigerant
cylinder, make sure the quick-release couplings are
not leaking.
R Only ever use external refrigerant cylinders
provided with safety valves and certified in line
with the applicable standards.
R Before switching off the ACS 810, make sure
all filling and drainage operations have been
completed. This prevents refrigerant escaping into
the environment.
Do not use compressed air with R134a.
Some air mixtures with R134a are highly
flammable. 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.
Robert Bosch GmbH
Safety regulations | ACS 810 | 5 | en
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 permitted.
R High temperatures and UV radiation may chemically
separate the R134a. The resultant products cause
coughing and nausea.
R R134a is not to be mixed with other refrigerants.
The mixing of refrigerants can damage the vehicle
air conditioning system.
4.2 Working on the vehicle
If high-voltage components or high-voltage
wires are inexpertly handled, there is a risk of
fatal injury from high voltages and the possible
transmission of current through the body.
R De-energization is only to be performed by a qualified
electrician, a qualified electrician for specific tasks
(hybrid), or a power systems engineer.
R Work on vehicles with high-voltage components
is only ever to be performed in a safe, de-
energized condition by persons with the minimum
qualification "Trained to perform electrical work".
R Even after deactivating the high-voltage vehicle
electrical system, the high-voltage battery may still
be live.
R The operating condition cannot be established
from any running noise, as the electric machine is
silent when stationary.
R In gear positions "P" and "N" the engine or electric
motor may start spontaneously depending on the
charge of the high-voltage battery.
R Never open or damage high-voltage batteries.
R On accident vehicles, never touch high-voltage
components or exposed high-voltage wires before
deactivating the high-voltage vehicle electrical system.
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en | 6 | ACS 810 | Safety regulations

4.3 Notes on operation 4.4 Maintenance work

! Observe the pertinent legal regulations or
directives to ensure safe handling of pressurized
devices.
R The ACS 810 must be operated in an environment
corresponding to the directive BGR 157 with
respect to the exchange of air.
R Observe local laws or directives so as to ensure the
safety of the pressurized device. The ACS 810 must
be constantly monitored when in operation. Never
leave the ACS 810 unattended when in operation.
R Position the ACS 810 on all four wheels on a flat,
vibration-proof surface such that proper operation
of the scales is guaranteed.
R The ACS 810 can be secured in position by locking
R Never perform any maintenance work which is not
expressly recommended in this manual. Contact
customer service if components have to be
replaced other than in the 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

the brake. Rated voltage 230 VAC ± 10 %

R The ACS 810 must always be transported in its Rated frequency 50 Hz
operating position. Never lay the ACS 810 on its Rated current 230 VAC 10 A
side, as oil could then escape from the vacuum Rated tripping current 30 mA
pump, or the built-in compressor could be Tripping switch C

damaged. Overview of safety devices:

R There are no additional safety systems for
protecting the ACS 810 against damage resulting Description Operation

from natural catastrophes.
R ACS 810 must be connected to a properly
grounded electrical connection.
R The vehicle A/C service using the ACS 810 must be
prepared and implemented such that the vehicle
air conditioning system circuit does not have to be
opened (for example by removing the radiator or
engine).
R Never remove any components from inside
the ACS 810 except for maintenance or repair
purposes.
R If damage to the ACS 810 is established, terminate
usage immediately and contact customer service.
R The service hoses and quick-release couplings
must be regularly checked for wear and replaced if
damaged.
WARNING: Warranty is not valid in all
cases of improper use of the machine and
if the machine is not submitted to periodic
ordinary and extraordinary maintenance
(according to PED directive 2014/68/
EU) provided in this original instructions.
The manufacturer therefore declines all
responsibilities for any damage resulting
from not observing all the instructions and
warnings provided to the user regarding
installation, use and maintenance.
Pressure switch Switches the compressor off if the normal
operating pressure is exceeded.
Safety valve The safety valve opens if the design
pressure is exceeded.
Fuse Interrupts the power supply to ACS 810 in
the event of too high current.
Vents The ACS 810 is provided with vents in
the bottom of the housing to ensure the
exchange of air even when switched off.
4.6 PED directive 2014/68/EU
The machine includes parts subject to PED EU
directive 2014/68/EU, Pressure Equipment Directive.
PED directive regulates all the pressurized part
defining for them categories based on volume-
pressure ratio and based on fluid refrigerant type.
Those parts then have not to be anyhow modified nor
removed. Under the responsibility of the owner, the
machine and parts falling in the scope of PED shall be
checked either during commissioning and periodically
fulfilling local country regulations and norms.
Parts in the scope of PED are:
R Tank.
R Pressure relieve valve.
R High pressure switch.
R Recovery group.
R Piping.
i Call Bosch service center to get technical
specifications for each part listed.

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 Product description | ACS 810 | 7 | en

5. Product description 5.1.2 Rear view

5.1 Description of unit

5.1.1 Front view 7
5 6

6 4

2
4

3 3
7

2
8 4
1

9
5

Fig. 2: Rear view

1 Service quick-release coupling (LP)
FV
_A
CS 2 Service quick-release coupling (HP)
81
0 3 Service hose (5 m)
10 4 Service hose mount
5 Rear wheels
6 Power cord (socket)
Fig. 1: Front view 7 Master switch
1 Valve high pressure (HP)
2 Valve low pressure (LP)
3 Printer
4 Display and control panel
5 Gage low-pressure pressure (LP)
6 Gage high-pressure valve (HP)
7 Pressure gage of internal refrigerant cylinder
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

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en | 8 | ACS 810 | Product description

5.1.3 Display and control panel 5.1.4 Selection and function keys
The display and control panel of the operating unit
control the menus and the service phases. Keys Name Operation

Refrigerant is extracted from the

Evacuation
vehicle.
R Control up R Upward cursor movement.
6 R Vacuum R A vacuum is generated.

R Control R Cursor movement to the right.

right R Vehicle air conditioning system
5 7
R Filling is filled with refrigerant.
4
R Control R Cursor movement to the left.
3
left R Automatic service run: Air
2 R Automatic conditioning service is carried
8 out according to saved
1 parameters.
R Control R Downward cursor movement.
10 9 down R Flush components of the
R Flushing vehicle air conditioning.
Fig. 3: Display and control panel Call up various function for
1 Flushing Menu service
2 Automatic service and data management.
3 Filling Call up databases:
4 Vacuum R USER SPECS
Database
5 Removal by suction R VEHICLE DATAS
6 LCD display
7 Key panel
8 Vehicle database Enter (E) Confirm and take over.
9 PS2 interface 1)
10 Function light

Stop Terminate and return.

For updating firmware/software or database
1)

Various functions are assigned to the <MENU>

function key in the ACS 810 software. The functions of
the keys are defined in the menu line of the ACS 810
software.

5.1.5 Input keys

The input keys can be used to enter letters, numbers
and special characters in the input boxes.

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 Program structure | ACS 810 | 9 | en

6. Program structure 6.6 Manual mode

Input Menu
6.1 Calibration and tare
SELECT PORTS
Input Menu ...

TANK CALIBRATION <RECOVERY>

+ <3> IN OIL CALIBRATION R Automatic emptying
1)
1.
2. Enter 1111. OUT OIL CALIBRATION 1) R Extraction
3. Confirm with E. R Oil drain
PRES. CALIBRATION
R Pressure test
TANK TARE
IN OIL TARE 1)
Input Menu
OUT OIL TARE 1)

SET VACUUM TIME

...
6.2 Settings
<VACUUM>
Input Menu
LANGUAGE Input Menu

1. + <3> DATE/TIME SELECT PORTS

2. Enter 2222. UNIT OF MEASURE ...
3. Confirm with E. HOSES LENGTH
<CHARGE>
CONTRAST
GARAGE ADDRESS
FLUSHING
6.7 Automatic mode
OIL SCALE 1)

UV DYE 1)
Input Menu
DATABASE UPDATE
SELECT PORTS
SERIAL NUMBER ...
EXPERT MODE
<AUTOMATIC>
6.3 Repair
Input Menu
6.8 Flush (optional)
CHANGE FILTER
1. + <3> CHANGE OIL Input Menu
2. Enter 5555. SET VACUUM TIME
3. Confirm with E. ...

<FLUSH>
6.4 Vehicle and customer data
Input Menu 1 Menu 2
6.9 Enter
STANDARD SPECS EUROPEAN DATABASE
USER SPECS SELECT MODEL : Input Menu
DELETE MODEL : Information on current filling
<Database>
ADD MODEL : capacities of fresh and used
oil bottles and the internal
VEHICLE DATAS
<ENTER> refrigerant cylinder
6.5 Menu
1)
Not supported for ACS 810 or without functionality
Input Menu 1 Menu 2
PERFORMANCE TESTS
DIAGNOSTIC
TANK FILLING
<Menu>
TANK RECYCLING
ZEROING OIL SCALES 1)

REPORT MANAGEMENT PRINT REPORT

EXPORT DATA
DELETE DATA

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en | 10 | ACS 810 | Hydraulics diagram

7. Hydraulics diagram
M2
HIGH
T2

EV10 EV3

M1
LOW EV5 EV6
T1 P1 EV1
EV8
P
11
2 M3
VU1

P
1

P2 3 F1

HP
V5 V6

F2 5
4
10
V1 V3 V4 V2

EV7

6 7
9
C
8

Des. Description Des. Description

1 Fresh oil tank F2 Combi filter
2 Vacuum pump VU1 Oil non-return valve
3 Expansion valve EV1 Vacuum solenoid valve
4 Evaporator/oil separator EV3 Flow solenoid valve
5 Compressor oil separator EV5 Recovery solenoid valve
6 Compressor EV6 Filling solenoid valve
7 Internal refrigerant cylinder EV7 Oil drain solenoid valve
8 Refrigerant cylinder scale EV8 Oil injection solenoid valve
9 Used oil bottle EV10 Refrigerant pump by-pass solenoid valve
10 Heat exchanger P1 Pressure sensor
11 Refrigerant pump P2 Pressure switch
T1 Low pressure hose V1 Tank vapour side hose valve
T2 High pressure hose V2 Tank liquid side hose valve
M1 Low pressure gage V3 Tank vapour side valve
M2 High pressure gage V4 Tank liquid side valve
M3 Internal refrigerant cylinder pressure gage V5 Safety valve
F1 Coarse filter V6 Non condensable drain valve

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 Service phases | ACS 810 | 11 | en

8. Service phases i The combo filter (F2) cleans the extracted

i This section describes all of the ACS 810 service
phases. In addition, it explains the hydraulic
and electric circuits by presenting the hydraulic
diagram and providing a brief description of the
components involved in each function.
8.1 Recovery
i In this service phase, the refrigerant is extracted
from the vehicle air conditioning system.
refrigerant of suspended particles and moisture.
i In the evaporator/oil separator (5), the oil taken
in from the compressor is separated from the
refrigerant and fed back to the compressor.
i If the pressure at sensor P1 falls below the
value saved in the software, the function stops
automatically, the program waits 5 minutes for a
pressure increase and, if necessary, restarts with a
second recovery cycle.

1. The ACS 810 is connected to the vehicle with the At the end of this phase, the solenoid valves EV10,
service hoses T1 and T2. EV3 and EV5 are closed and the compressor 6 is
2. Open the service quick-release coupling valves. turned off.
? The pressure on the high and low pressure side
of the vehicle air conditioning system is indicat-
ed on the pressure gages M1 and M2.

i Opening the HP and LP valves on the ACS 810

causes the refrigerant to flow to the solenoid valves
EV10 (open) and EV3 (closed).

i The pressure sensor P1 checks the pressure of the

vehicle air conditioning system (whether or not
there is refrigerant in the vehicle air conditioning
system).

3. starts extraction of the refrigerant.

? 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 conditioning system
is separated from the refrigerant and routed into
the used oil bottle.
R The refrigerant then flows on through the combo
filter (F2) and the compressor (6) into the
condenser/separator (5), and finally into the
internal refrigerant cylinder.

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en | 12 | ACS 810 | Service phases

M2
HIGH
T2

EV10 EV3

M1
LOW EV5 EV6
T1 P1 EV1
EV8
P
11
2 M3
VU1

P
1

P2 3 F1

HP
V5 V6

F2 5
4
10
V1 V3 V4 V2

EV7

6 7
9
C
8

Des. Description Des. Description

1 Fresh oil tank F2 Combi filter
2 Vacuum pump VU1 Oil non-return valve
3 Expansion valve EV1 Vacuum solenoid valve
4 Evaporator/oil separator EV3 Flow solenoid valve
5 Compressor oil separator EV5 Recovery solenoid valve
6 Compressor EV6 Filling solenoid valve
7 Internal refrigerant cylinder EV7 Oil drain solenoid valve
8 Refrigerant cylinder scale EV8 Oil injection solenoid valve
9 Used oil bottle EV10 Refrigerant pump by-pass solenoid valve
10 Heat exchanger P1 Pressure sensor
11 Refrigerant pump P2 Pressure switch
T1 Low pressure hose V1 Tank vapour side hose valve
T2 High pressure hose V2 Tank liquid side hose valve
M1 Low pressure gage V3 Tank vapour side valve
M2 High pressure gage V4 Tank liquid side valve
M3 Internal refrigerant cylinder pressure gage V5 Safety valve
F1 Coarse filter V6 Non condensable drain valve

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 Service phases | ACS 810 | 13 | en

8.2 Draining oil into the used oil bottle

At the end of recovery, the solenoid valve EV7 opens
and the oil previously separated out in the evaporator/
oil separator (4) drains into the used oil bottle (9).

M2
HIGH
T2

EV10 EV3

M1
LOW EV5 EV6
T1 P1 EV1
EV8
P
11
2 M3
VU1

P
1

P2 3 F1

HP
V5 V6

F2 5
4
10
V1 V3 V4 V2

EV7

6 7
9
C
8

Des. Description Des. Description

1 Fresh oil tank F2 Combi filter
2 Vacuum pump VU1 Oil non-return valve
3 Expansion valve EV1 Vacuum solenoid valve
4 Evaporator/oil separator EV3 Flow solenoid valve
5 Compressor oil separator EV5 Recovery solenoid valve
6 Compressor EV6 Filling solenoid valve
7 Internal refrigerant cylinder EV7 Oil drain solenoid valve
8 Refrigerant cylinder scale EV8 Oil injection solenoid valve
9 Used oil bottle EV10 Refrigerant pump by-pass solenoid valve
10 Heat exchanger P1 Pressure sensor
11 Refrigerant pump P2 Pressure switch
T1 Low pressure hose V1 Tank vapour side hose valve
T2 High pressure hose V2 Tank liquid side hose valve
M1 Low pressure gage V3 Tank vapour side valve
M2 High pressure gage V4 Tank liquid side valve
M3 Internal refrigerant cylinder pressure gage V5 Safety valve
F1 Coarse filter V6 Non condensable drain valve

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en | 14 | ACS 810 | Service phases
8.3 Vacuum phase
i During vacuum generation in the vehicle air
conditioning system, the refrigerant is prepared
in the internal refrigerant cylinder to remove the
non-condensing gases before filling and to filter the
refrigerant.
1. The ACS 810 is connected to the vehicle with the
service hoses T1 and T2.
2. Open the service quick-release coupling valves.
? The pressure on the high and low pressure side
of the vehicle air conditioning system is indicat-
ed on the pressure gages M1 and M2.
i Opening the HP and LP valves on the ACS 810
causes the refrigerant to flow to 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).
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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 value, there is still
refrigerant in the vehicle air conditioning system,
and it must be extracted before vacuum generation.
3. Press the <Vacuum> key.
? EV1 and EV10 are opened
? The vacuum pump (2) starts.
i The vacuum pump generates a maximum vacuum
of 0,033 mbar. This depends on the duration of
vacuum generation.
i The refrigerant in the internal refrigerant cylinder
is fed through the internal refrigerant circuit and
prepared in each vacuum phase.
Robert Bosch GmbH
 Service phases | ACS 810 | 15 | en

M2
HIGH
T2

EV10 EV3

M1
LOW EV5 EV6
T1 P1 EV1
EV8
P
11
2 M3
VU1

P
1

P2 3 F1

HP
V5 V6

F2 5
4
10
V1 V3 V4 V2

EV7

6 7
9
C
8

Des. Description Des. Description

1 Fresh oil tank F2 Combi filter
2 Vacuum pump VU1 Oil non-return valve
3 Expansion valve EV1 Vacuum solenoid valve
4 Evaporator/oil separator EV3 Flow solenoid valve
5 Compressor oil separator EV5 Recovery solenoid valve
6 Compressor EV6 Filling solenoid valve
7 Internal refrigerant cylinder EV7 Oil drain solenoid valve
8 Refrigerant cylinder scale EV8 Oil injection solenoid valve
9 Used oil bottle EV10 Refrigerant pump by-pass solenoid valve
10 Heat exchanger P1 Pressure sensor
11 Refrigerant pump P2 Pressure switch
T1 Low pressure hose V1 Tank vapour side hose valve
T2 High pressure hose V2 Tank liquid side hose valve
M1 Low pressure gage V3 Tank vapour side valve
M2 High pressure gage V4 Tank liquid side valve
M3 Internal refrigerant cylinder pressure gage V5 Safety valve
F1 Coarse filter V6 Non condensable drain valve

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en | 16 | ACS 810 | Service phases

8.4 Leak test i If the pressure at P1 falls below the value saved in
the software during the leak test, an error message
i The leak test starts after the vacuum phase. is displayed.

i The HP and LP valves are open and all solenoid

valves are closed. After the specified vacuum time
has elapsed, EV1 is closed to perform the leak test.

M2
HIGH
T2

EV10 EV3

M1
LOW EV5 EV6
T1 P1 EV1
EV8
P
11
2 M3
VU1

P
1

P2 3 F1

HP
V5 V6

F2 5
4
10
V1 V3 V4 V2

EV7

6 7
9
C
8

Des. Description Des. Description

1 Fresh oil tank F2 Combi filter
2 Vacuum pump VU1 Oil non-return valve
3 Expansion valve EV1 Vacuum solenoid valve
4 Evaporator/oil separator EV3 Flow solenoid valve
5 Compressor oil separator EV5 Recovery solenoid valve
6 Compressor EV6 Filling solenoid valve
7 Internal refrigerant cylinder EV7 Oil drain solenoid valve
8 Refrigerant cylinder scale EV8 Oil injection solenoid valve
9 Used oil bottle EV10 Refrigerant pump by-pass solenoid valve
10 Heat exchanger P1 Pressure sensor
11 Refrigerant pump P2 Pressure switch
T1 Low pressure hose V1 Tank vapour side hose valve
T2 High pressure hose V2 Tank liquid side hose valve
M1 Low pressure gage V3 Tank vapour side valve
M2 High pressure gage V4 Tank liquid side valve
M3 Internal refrigerant cylinder pressure gage V5 Safety valve
F1 Coarse filter V6 Non condensable drain valve

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 Service phases | ACS 810 | 17 | en

8.5 Refrigerant preparation i In that way, refrigerant is sucked from internal

refrigerant cylinder (7) and is conveyed through the
1. Press the <MENU> key. filter F1, the expansion valve (3), the Evaporator/ oil
2. Select <R134a PREPARATION> and confirm with E. separator (4) until reaching the internal refrigerant
" ACS 810 starts internal preparation of the refrigerant. cylinder (7) again, as it happens in the recovery stage.
" EV5 and EV6 are opened and the compressor (6)
starts. i Internal preparation of the refrigerant is the same
process that the ACS 810 performs in the recovery
M2 phase to clean the refrigerant recovered from the
HIGH vehicle air conditioning system.
T2

EV10 EV3

M1
LOW EV5 EV6
T1 P1 EV1
EV8
P
11
2 M3
VU1

P
1

P2 3 F1

HP
V5 V6

F2 5
4
10
V1 V3 V4 V2

EV7

6 7
9
C
8

Des. Description Des. Description

1 Fresh oil tank F2 Combi filter
2 Vacuum pump VU1 Oil non-return valve
3 Expansion valve EV1 Vacuum solenoid valve
4 Evaporator/oil separator EV3 Flow solenoid valve
5 Compressor oil separator EV5 Recovery solenoid valve
6 Compressor EV6 Filling solenoid valve
7 Internal refrigerant cylinder EV7 Oil drain solenoid valve
8 Refrigerant cylinder scale EV8 Oil injection solenoid valve
9 Used oil bottle EV10 Refrigerant pump by-pass solenoid valve
10 Heat exchanger P1 Pressure sensor
11 Refrigerant pump P2 Pressure switch
T1 Low pressure hose V1 Tank vapour side hose valve
T2 High pressure hose V2 Tank liquid side hose valve
M1 Low pressure gage V3 Tank vapour side valve
M2 High pressure gage V4 Tank liquid side valve
M3 Internal refrigerant cylinder pressure gage V5 Safety valve
F1 Coarse filter V6 Non condensable drain valve

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en | 18 | ACS 810 | Service phases

8.6 Fresh oil filling
i You can only fill new fresh oil into a vehicle A/C
system, if there is vacuum inside the A/C system.
So you have to start first the vacuum phase.
i After evacuating the vehicle A/C system, recovered
oil has to be replaced with new oil. The oil
replenishing occurs by pressure difference.
M2
HIGH
T2
1. Open valve of service quick coupler T2.
2. Open HP valve.
3. Open solenoid valve EV8.
? The pressure difference makes fresh oil in the
graduated bottle be sucked inside the vehicle A/C
system.
i As buses often have huge quantities of oil (even
more than 1 kg), for the oil replenishing the
refrigerant pump (11) is also used that allows the
replenishing of the hole quantity needed.
4. After filling fresh oil, close solenoid valve EV8 and
switch off the refrigerant pump (11).

EV10 EV3

M1
LOW EV5 EV6
T1 P1 EV1
EV8
P
11
2 M3
VU1

P
1

P2 3 F1

HP
V5 V6

F2 5
4
10
V1 V3 V4 V2

EV7

6 7
9
C
8

Des. Description Des. Description

1 Fresh oil tank F2 Combi filter
2 Vacuum pump VU1 Oil non-return valve
3 Expansion valve EV1 Vacuum solenoid valve
4 Evaporator/oil separator EV3 Flow solenoid valve
5 Compressor oil separator EV5 Recovery solenoid valve
6 Compressor EV6 Filling solenoid valve
7 Internal refrigerant cylinder EV7 Oil drain solenoid valve
8 Refrigerant cylinder scale EV8 Oil injection solenoid valve
9 Used oil bottle EV10 Refrigerant pump by-pass solenoid valve
10 Heat exchanger P1 Pressure sensor
11 Refrigerant pump P2 Pressure switch
T1 Low pressure hose V1 Tank vapour side hose valve
T2 High pressure hose V2 Tank liquid side hose valve
M1 Low pressure gage V3 Tank vapour side valve
M2 High pressure gage V4 Tank liquid side valve
M3 Internal refrigerant cylinder pressure gage V5 Safety valve
F1 Coarse filter V6 Non condensable drain valve

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 Service phases | ACS 810 | 19 | en

8.7 Filling refrigerant

1. Press the key .
i The refrigerant in the internal refrigerant cylinder is ? EV3, EV6 and EV10 are opened.
used for filling the vehicle air conditioning system. ? Refrigerant pump (11) will start.
? Refrigerant flows from the internal refrigerant
i Refrigerant can only be added to a vehicle air cylinder through valves V4 and V2, through the
conditioning system under a vacuum. The vacuum solenoid valves EV3, EV6 and EV10, the HP valve
phase must therefore be performed before filling. (when filling on the high pressure side) and
along the service hose T2 into the vehicle air
conditioning system.
2. The filling quantity is checked by the scale (8),
M2 which end the filling process after the quantity
HIGH
previously entered in the service process.
T2

EV10 EV3

M1
LOW EV5 EV6
T1 P1 EV1
EV8
P
11
2 M3
VU1

P
1

P2 3 F1

HP
V5 V6

F2 5
4
10
V1 V3 V4 V2

EV7

6 7
9
C
8

Des. Description Des. Description

1 Fresh oil tank F2 Combi filter
2 Vacuum pump VU1 Oil non-return valve
3 Expansion valve EV1 Vacuum solenoid valve
4 Evaporator/oil separator EV3 Flow solenoid valve
5 Compressor oil separator EV5 Recovery solenoid valve
6 Compressor EV6 Filling solenoid valve
7 Internal refrigerant cylinder EV7 Oil drain solenoid valve
8 Refrigerant cylinder scale EV8 Oil injection solenoid valve
9 Used oil bottle EV10 Refrigerant pump by-pass solenoid valve
10 Heat exchanger P1 Pressure sensor
11 Refrigerant pump P2 Pressure switch
T1 Low pressure hose V1 Tank vapour side hose valve
T2 High pressure hose V2 Tank liquid side hose valve
M1 Low pressure gage V3 Tank vapour side valve
M2 High pressure gage V4 Tank liquid side valve
M3 Internal refrigerant cylinder pressure gage V5 Safety valve
F1 Coarse filter V6 Non condensable drain valve

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en | 20 | ACS 810 | Service phases

8.8 Separating and returning i This oil is separated from the refrigerant in the
compressor oil compressor oil separator (5) and is then fed back
to the compressor (6).
i During the recovery phase and preparation of the
refrigerant, small quantities of compressor oil get
into the internal circuit.

M2
HIGH
T2

EV10 EV3

M1
LOW EV5 EV6
T1 P1 EV1
EV8
P
11
2 M3
VU1

P
1

P2 3 F1

HP
V5 V6

F2 5
4
10
V1 V3 V4 V2

EV7

6 7
9
C
8

Des. Description Des. Description

1 Fresh oil tank F2 Combi filter
2 Vacuum pump VU1 Oil non-return valve
3 Expansion valve EV1 Vacuum solenoid valve
4 Evaporator/oil separator EV3 Flow solenoid valve
5 Compressor oil separator EV5 Recovery solenoid valve
6 Compressor EV6 Filling solenoid valve
7 Internal refrigerant cylinder EV7 Oil drain solenoid valve
8 Refrigerant cylinder scale EV8 Oil injection solenoid valve
9 Used oil bottle EV10 Refrigerant pump by-pass solenoid valve
10 Heat exchanger P1 Pressure sensor
11 Refrigerant pump P2 Pressure switch
T1 Low pressure hose V1 Tank vapour side hose valve
T2 High pressure hose V2 Tank liquid side hose valve
M1 Low pressure gage V3 Tank vapour side valve
M2 High pressure gage V4 Tank liquid side valve
M3 Internal refrigerant cylinder pressure gage V5 Safety valve
F1 Coarse filter V6 Non condensable drain valve

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 Service phases | ACS 810 | 21 | en

8.9 Non-condensing gases i The pressure of the internal refrigerant cylinder

increases during the recovery phase and when
i The drain valve (V6) for non-condensing gases preparing the refrigerant.
opens if the pressure in the refrigerant cylinder
is higher than the set opening pressure (normally i The safety valve (V5) opens at a factory set
between 12 and 14 bar). pressure (approx. 18 bar) to limit the pressure in
the internal refrigerant cylinder.
M2
HIGH
T2

EV10 EV3

M1
LOW EV5 EV6
T1 P1 EV1
EV8
P
11
2 M3
VU1

P
1

P2 3 F1

HP
V5 V6

F2 5
4
10
V1 V3 V4 V2

EV7

6 7
9
C
8

Des. Description Des. Description

1 Fresh oil tank F2 Combi filter
2 Vacuum pump VU1 Oil non-return valve
3 Expansion valve EV1 Vacuum solenoid valve
4 Evaporator/oil separator EV3 Flow solenoid valve
5 Compressor oil separator EV5 Recovery solenoid valve
6 Compressor EV6 Filling solenoid valve
7 Internal refrigerant cylinder EV7 Oil drain solenoid valve
8 Refrigerant cylinder scale EV8 Oil injection solenoid valve
9 Used oil bottle EV10 Refrigerant pump by-pass solenoid valve
10 Heat exchanger P1 Pressure sensor
11 Refrigerant pump P2 Pressure switch
T1 Low pressure hose V1 Tank vapour side hose valve
T2 High pressure hose V2 Tank liquid side hose valve
M1 Low pressure gage V3 Tank vapour side valve
M2 High pressure gage V4 Tank liquid side valve
M3 Internal refrigerant cylinder pressure gage V5 Safety valve
F1 Coarse filter V6 Non condensable drain valve

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en | 22 | ACS 810 | Troubleshooting

9. Troubleshooting
9.1 Service messages
Service message Actions
CHANGE OIL Change vacuum pump oil
(see section 12.7.1)
REPLACE FILTER Replace combo filter
(see section 12.6.1)

9.2 Fault messages

failure indication Actions
HIGH PRESSURE There is excess pressure at the outlet of the compressor.
Turn off the ACS 810 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.
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 system.
A/C SYSTEM FULL There is refrigerant in the air conditioning system.
INCOMPLETE CHARGE The filling time exceeds the safe maximum duration set.
Pressure in internal refrigerant cylinder corresponds to pressure in vehicle
air conditioning system.

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10. Emptying the ACS 810
! When repairing internal components, we
recommend extracting the internal hoses on the
ACS 810 to ensure that no refrigerant can escape
when the hose lines are opened.
i This extraction is carried out by automatic
emptying or, if there is a technical defect, by using
a second A/C service unit.
Warning – Risk of frostbite from escaping
refrigerant
Refrigerant causes severe frostbite on the
skin.
¶ Check the service hoses for damage.
¶ Firmly connect the service quick-release
couplings to the service hoses.
¶ Wear safety goggles.
¶ Wear protective gloves.
10.1 Automatic emptying
i Refrigerant in the internal hoses is extracted into
the internal refrigerant cylinder.
1. Service hoses (T1, T2) are not connected to the
vehicle.
2. Close service quick-release couplings.
3. Open HP and LP valves on the ACS 810.
4. Start recovery.
" Automatic emptying is performed.
Robert Bosch GmbH
Emptying the ACS 810 | ACS 810 | 23 | en
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 power supply for the ACS 810
must be disconnected before extraction.
1. Close shutoff valves V1, V3, V2, and V4 on the
refrigerant cylinder and disconnect the blue and
red hoses from the refrigerant cylinder.
2. Connect the blue hose to the low pressure side of
the second A/C service unit.
3. Connect the red hose to the high pressure side of
the second A/C service unit.
4. Open the valves V1 and V2.
5. Open both valves on the second A/C service unit
and recover the refrigerant from the first, defective
A/C service unit.
? A pressure increase test is performed at the end
of recovery.
6. Close the two valves on the second A/C service
unit and disconnect the hoses from the refrigerant
cylinder.
" Repairs can be performed.
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en | 24 | ACS 810 | TROUBLESHOOTING AND ANALYSIS
11. TROUBLESHOOTING AND
ANALYSIS
i This section briefly describes the various faults,
and the components that can cause the faults.
! Before carrying out any service intervention, reduce
the ACS 810 pressure so that no refrigerant is
released.
11.1 Faults during recovery
11.1.1 Compressor starts
i EV3 and EV5 are closed for automatic self-cleaning.
The pressure at the pressure gages may not
change.
1. Service hoses (T1, T2) are not connected to the
vehicle.
2. Close service quick-release couplings.
3. Open HP and LP valves on the ACS 810.
i If the pressure at the pressure gages decreases
during self cleaning, check whether EV3 and EV5
are not supplied with power.
Power applied:
? Computer PCB (control PCB) defective.
" Replace computer PCB (control PCB).
No voltage applied:
? Solenoid valve leaking.
" Clean or replace solenoid valve.
i If the pressure at the pressure gages does not
decrease after self cleaning, check whether EV3,
EV5, and EV10 are supplied 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).
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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 2 and 2.3 bar.
4. Check compressor (6).
ACS 810 ends the recovery phase but the pressure at
the pressure gages does not change.
1. Valves V1, V2, V3, and V4 must be open.
2. HP and LP valves must be open.
3. Check that pressure sensor (P1) functions
properly.
11.1.2 Compressor does not start
1. Check fuses F 2 and F 3 (T 12.5 A) on control PCB.
2. Check whether 12 Volt (DC) is applied at the
compressor relay coil.
3. Check whether the compressor relay trips after
pressing the recovery key. It may be necessary to
replace the keypad or the control card.
4. Check whether 230 Volt is applied at the
compressor relay output pins.
? If no voltage is applied, the computer PCB is de-
fective and must be replaced.
? If voltage is applied, the current consumption
must be measured.
5. Measure current consumption. At 0 A or >=8 A the
compressor must be replaced.
Robert Bosch GmbH
 TROUBLESHOOTING AND ANALYSIS | ACS 810 | 25 |
11.1.3 Fault messages that can occur during
recovery
"CYLINDER FULL"
i Check the weight of the internal refrigerant
cylinder and reduce the quantity of refrigerant in
the internal refrigerant cylinder.
"PRESSURE VALVE TOO HIGH"
1. Valves V1, V2, V3, and V4 must be open.
2. Check contacts for pressure switch (P2).
i If the pressure is below 16 bar, voltage must be
present between pin 1 and pin 2, while pin 1 and
pin 4 are open.
i If the pressure is above 16 bar, the contacts
between pin 1 and pin 2 open, while the pin 1 and
pin 4 contacts close.
? If the pressure switch (P2) does not work in
this way, replace it.
? If the pressure switch is working correctly,
check the wiring and the control PCB.
i If no fault can be identified with the pressure
switch (P2), the line to the internal refrigerant
cylinder must be checked for clogging.
11.1.4 Other fault messages
Please see chapter 9.2
Robert Bosch GmbH
en
11.2 Faults during the vacuum phase
11.2.1 The vacuum pump starts
i The vacuum pump starts but no vacuum is
generated in the vehicle 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 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 minutes).
6. If a vacuum of less than 0,033 mbar is reached:
Check whether voltage is present at EV1 and EV10.
7. Valves EV8 and EV9 must not leak.
8. Check whether EV1 switches
? If voltage is present and EV1 switches, replace
the vacuum pump.
¶ Check the pump vacuum output (the pressure must
fall to less than 0,033 mbar within 3 minutes).
11.2.2 The vacuum pump does not start
1. Check the oil level in the vacuum pump.
2. Check whether the vacuum pump is turned on (on/
off switch on the rear of the vacuum pump).
3. Check fuses F 2 and F 3 (12.5 A) on the control
PCB.
4. Check whether the relay trips after pressing the
vacuum key.
5. Check whether the vacuum pump is being supplied
with power (230 Volt).
i A voltage of 12 Volt (DC) must be present at the
pump relay coil; 230 Volt must be present at the
output contacts. If one of these voltages is not
present, the computer PCB must be replaced.
" Replace the vacuum pump if it does not start.
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en | 26 | ACS 810 | TROUBLESHOOTING AND ANALYSIS
11.2.3 Fault message that can occur during the
vacuum phase
"A/C SYSTEM FULL"
¶ Check the pressure at the pressure gages M 1 and
M 2.
? Pressure above 0.3 bar, perform recovery.
? Pressure below 0.3 bar, adjust pressure sensor
P 1.
" If the message is still displayed, replace the pressure
sensor.
" If the message is still displayed, replace the computer
PCB.
11.3 Faults during refrigerant preparation
1. Check hose connections on the internal refrigerant
cylinder.
2. Valves V1, V2, V3 and V4 must be open.
3. Check EV7 for leaks.
4. Check filter F1 for impurities and clean with
compressed air.
5. Check the expansion valve (3) for the correct
pressure value (2 - 2.3 bar).
6. Check whether the internal refrigerant circuit is
soiled or clogged.
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
drained
¶ Mechanically test drain valve V6.
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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 scale are not blocked.
i You must ensure that the control PCB applies
the set weight value; if not, check whether the
refrigerant cylinder contains sufficient refrigerant
for the filling process.
i Check whether EV6 and EV3 are supplied with
power. If so, they must be replaced. If they are not
supplied, the connecting cables and the control
PCB must be checked.
If the refrigerant pump does not work, it is necessary
to:
1. Check the condition of the flying fuse (800 mA
delayed) inside the power box.
i Be sure that there is a 230 Volt during the filling
phase, but only after the switching off of the EV10
solenoid valve.
i Be sure that there is 12 Volt (DC) direct current
on the refrigerant pump relay coil; be sure are 230
Volt on the outlet contacts. In case one of the two
voltages is absent, replace the control PCB.
11.5.2 Other fault messages
Please see chapter 9.2
Robert Bosch GmbH
 Component test and maintenance | ACS 810 | 27 | en

12. Component test and 12.3 Pressure switch P2

maintenance
i The pressure switch is normally closed between
contacts 1 and 2, and open between contacts 1
12.1 Vacuum pump and 4. The pressure switch opens at 16 bar.

! The vacuum pump oil must always be changed after To check the pressure switch, carry out the following
30 hours of operation. steps:
1. Close V1 - V4.
Property Value/range
2. Remove the red hose from the internal refrigerant
Operating voltage 230 VAC ± 10 % cylinder and connect the red service hose to the
Frequency 50/60 Hz internal refrigerant cylinder.
Vacuum pump oil filling capacity 590 ml 3. Close both valves on the refrigerant cylinder.
Output 283 l/min 4. Remove the blue hose from the internal refrigerant
Max. vacuum 0,033 mbar
cylinder and connect a pressure gage using a
T-piece.
To check correct operation of the pump, carry out the 5. Open V4.
following steps: 6. Open V1.
1. Check the oil level in the vacuum pump. 7. Start the recovery function.
8. As soon as the pressure reaches 16 bar, recovery
i The oil level should be in the middle of the must be ended, and the message
sight glass between the "full" and "empty" marks. PRESSURE VALUE TOO HIGH is displayed.
9. Drain the pressure into the internal refrigerant
2. Attach pressure gage to intake connection. cylinder by opening the high pressure valve.
3. Start vacuum generation.
" A vacuum of 0,033 mbar must be achieved. i When replacing the pressure switch, a special
weight sealant must be used.
12.2 Pressure sensor P1
1. Check whether a voltage of 24 Volt (DC) is present 12.4 Expansion valve
between pin 1 (-) and pin 2 (+).
i The expansion valve is a pressure control valve
i If no voltage is present, check the control PCB and that is set to a value between 2 and 2.3 bar and
replace if necessary. maintains a constant pressure before the oil
separator.
2. Check whether an output signal is present between
pin 1 (-) and pin 3 (+). ! The refrigerant cylinder must contain at least 6 kg
of refrigerant.
i The output signal is between 0 V and 10 Volt, i.e.
1.0 Volt corresponds to 1.6 bar. If the pressure 1. Connect the low pressure service hose to the
gage shows 3 bar relative (4 bar absolute), the connection after the expansion valve using the
voltage must be 2.5 Volt. adapter supplied.
2. Close HP and LP valves.
i When replacing the pressure sensor, a special 3. Start the recycling function.
thread sealant (e.g. Loctite 542) must be used. " After around 10 minutes, the pressure value must be
between 2 and 2.3 bar.

i Adjust the value by turning the hexagonal screw in

the expansion valve upper part, if the pressure is
not within the indicated range (between 2 and
2,3 bar).
$ Clockwise to increase the value.
$ Counterclockwise to decrease the value.

i In case of replacement, use the right o-rings and

perform the calibration as instruction above.

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en | 28 | ACS 810 | Component test and maintenance
12.5 Periodic check of the non-condensable
gas purge valve
CAUTION: Only qualified technicians who
are authorized to use refrigerants may
carry out this procedure.
¶ Wear personal protective equipment
(glasses and gloves).
¶ Do not go in front of the discharge flow.
¶ The valve does not require adjustment or
lubrication. Do not tamper with it in any
way.
1 WARNING – Risk of frostbite from
Fig. 4: Periodic check of the non-condensable gas purge valve
1 Non-condensable gas purge valve
i To ensure that the valve remains in good working
condition, periodically make it trip by pulling the
metal ring at the top.
i While doing this, make sure that the pressure in the
cylinder is at least 8–10 bar.
i The valve should open sharply and then close
firmly as soon as the metal ring is released.
! This action must be quick, and do not repeat it
until only non-condensable gas is purged, with no
refrigerant.
i The frequency depends on the valve condition,
and specifically on its cleanliness, which normally
depends on whether there are residues in the
cylinder or not.
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12.6 Combo 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.
escaping refrigerant
Refrigerant causes severe frostbite on the
skin.
¶ Check the service hoses for damage.
¶ Firmly connect the service quick-release
couplings to the service hoses.
¶ Wear safety goggles.
¶ Wear protective gloves.
i After 150 kg of refrigerant have been
processed through the filter, the message
"REPLACE FILTER" appears on the display. When
this message appears, contact customer service to
order a new filter.
i It is advisable to have the combo filter changed by
customer service.
! Make sure the old sealing rings are removed before
securing 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
connections when changing the filter.
! Never re-use an old filter.
! Observe the ACS 810 menu prompting.
1. Call up start screen.
2. Open the HP and LP valves on the display and
control panel.
3. Press <Recovery>.
? ACS 810 performs a self-cleaning process, then
the recovery phase.
i Pressure gauge must reach 0 bar.
Robert Bosch GmbH
 Component test and maintenance | ACS 810 | 29 | en

4. Close the HP and LP valves on the display and
control panel.
5. Switch off ACS 810.
6. Disconnect ACS 810 from power supply.
7. Carefully open the ACS 810 housing.
8. Carefully remove the old Combo filter.
9. Insert the new Combo filter with the new sealing
rings and ensure correct positioning of the sealing
rings.
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 kg) of filtered refriger-
ant is displayed.
5. Press <MENU> until filtered refrigerant quantity is
reset to zero.
" Filter change interval is reset.

i Return with <Stop>.

Fig. 5: Combo filter

10. Close the housing.

" The filter is replaced.

i Return with <Stop>.

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en | 30 | ACS 810 | Component test and maintenance
12.7 Vacuum pump
12.7.1 Changing vacuum pump oil
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.
ATTENTION – Risk of burns from hot
surfaces
Contact with the hot vacuum pump
surface will cause severe burns.
¶ Allow the vacuum pump to cool down.
¶ Wear protective gloves.
i The vacuum pump oil must always be changed after
30 hours of operation. The prompt "REPLACE OIL"
appears on the screen when the vacuum pump oil
needs changing.
i Use the vacuum pump oil (item number
SP00100086) as specified by Bosch.
3 1
Fig. 6: Vacuum pump
1 Sight class
2 Oil fill plug
3 Drain plug
1 689 975 253 | 2021-01-26
! 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 vacuum pump oil.
6. Start the vacuum phase.
7. Check the oil level (sight glass).
i The oil level should be in the middle between the
"full" and "empty" marks.
12.7.2 Reset of oil change interval
! 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 OIL" with o u and confirm with
E.
? Current runtime of vacuum pump is displayed.
5. Press <MENU> until vacuum pump runtime is set to
zero.
" Oil change interval is reset.
i Return with <Stop>.
Robert Bosch GmbH
 Calibration | ACS 810 | 31 | en

13. Calibration 13.2 Tara values

The following Tara values for the Internal refrigerant
13.1 Internal refrigerant cylinder scale cylinder is set from the factory.

i Detach the rear panel and remove the refrigerant Internal refrigerant cylinder:
cylinder from the scale. ACS 810 = 18.5 kg

i It is not necessary to detach the lines from the Setting tara value:
refrigerant cylinder. If you want to detach the 1. Select the Tara value (Tara Internal refrigerant
hoses, close the valves on the hoses and on the cylinder).
cylinder. 2. Set the weight.
3. Confirm with <Enter>.
1. Call up the start screen.
2. Press <3> and <Flush> simultaneously and release. i Important note for older software versions:
? The message ENTER CODE 0000 is displayed. The Tara values are NOT displayed. You always will
3. Enter the value 1111 and confirm with E. see just value "0" in the menu where you can set
4. Select "TANK CALIBRATION" and confirm with the Tara value.
ENTER.
? The display shows ! If you confirm with <Enter> in this menu, you set
ZERO CALIBRATION. "0" as new Tara value. If you don't want to change
5. With an empty weighing plate, enter the figure the current value, you have to press the key "Stop".
00.00 and confirm 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>.

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en | 32 | ACS 810 | Calibration
13.3 Pressure sensor
13.3.1 Checking the adjustment
1. Call up the start screen.
2. Press <3> and <Flush> simultaneously and release.
? The message ENTER CODE 0000 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 (the typical value is 1.000
bar).
13.3.2 Adjusting the pressure sensor
i The pressure sensor is adjusted on the control PCB
using the simulator, as the pressure sensor has
been officially calibrated in the factory.
i Pressure sensor 0 bar / 16 bar absolute
-1 bar / +15 bar relative.
1. Disconnect the pressure sensor from the control
PCB.
2. Connect the simulator to the control PCB.
3. Connect a multimeter to the simulator.
4. Call up the start screen.
5. Press <3> and <Flush> simultaneously and release.
? The message ENTER CODE 0000 is displayed.
6. Enter 1111 and confirm with E .
7. Select "PRES. CALIBRATION" with o u and
confirm with E .
? ZERO CALIBRATION is displayed.
8. Turn the potentiometer on the simulator until a
voltage 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
sensor.
i Return with <Stop>.
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i If the simulator is not available, a simplified
adjustment can be performed. This process
definitely guarantees that the ACS 810 will function
perfectly.
1. Turn on the ACS 810.
2. Open the HP and LP valves on the display and
control panel.
3. Start the vacuum function and maintain the vacuum
in the hoses for 5 minutes (this subjects the
pressure sensor to a vacuum).
4. After 5 minutes, stop the vacuum function and
check on the pressure gages that there are no
leaks.
5. Call up the start screen.
6. Press <3> and <Flush> simultaneously and release.
? The message ENTER CODE 0000 is displayed.
7. Enter 1111 and confirm with E .
8. Select "PRESSURE CALIBRATION" and confirm
with E .
? ZERO CALIBRATION is displayed.
9. Enter the value 0.000 on the keypad and confirm
with E.
? WEIGHT CALIBRATION is displayed.
10. Detach the service hoses and set the pressure
sensor to atmospheric pressure.
11. Enter the value 1.000 on the keypad and confirm
with E.
? The menu containing the functions appears on
the display again.
i Return with <Stop>.
12. Perform the adjustment check described above
(see section 13.3.1).
Robert Bosch GmbH
 Component test | ACS 810 | 33 | en

14. Component test 14.3 Control PCB input signal

14.1 LCD ! Follow the additional ACS 810 menu prompting.

! Follow the additional ACS 810 menu prompting.
1. Call up the start screen.
2. Press <3> and <Flush> simultaneously and release.
? The message ENTER CODE 0000 is displayed.
3. Enter 1515 and confirm with E .
4. Select "DISPLAY TEST" with o u and confirm
with E .
1. Call up the start screen.
2. Press <3> and <Flush> simultaneously and release.
? The message ENTER CODE 0000 is displayed.
3. Enter 1515 and confirm with E .
4. Select "INPUTS TEST" with o u and confirm with
E .
i Return with <Stop>.

i Return with <Stop> ? In order, the screen shows:

$ Weight of the internal refrigerant cylinder
i All display pixels, followed by the LED displays, are $ Weight of the fresh oil bottle (not used)
activated in sequence to ensure that they function $ Weight o the used oil bottle (not used)
properly. $ Pressure sensor value

14.2 Outputs i The values measured by the scales are absolute

! During this process, parts of the refrigerant circuit
are opened that may be pressurized. Therefore,
make sure beforehand that the pressure has been
drained from the refrigerant circuit (see section
10.1).
! Follow the additional ACS 810 menu prompting.
1. Call up the start screen.
2. Press <3> and <Flush> simultaneously and release.
? The message ENTER CODE 0000 is displayed.
3. Enter 1515 and confirm with E .
4. Select "OUTPUTS TEST" with o u and confirm
with E .
i Return with <Stop>
values, that means the real weight on the scales.
14.4 Printer
i This function starts a short test print.
! Heed 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 1515 and confirm with E .
4. Select "PRINTER TEST " with o u and confirm
with E .
i Return with <Stop>.

i As soon as the outputs function test has 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 (refrigerant pump)
Solenoid valve EV10 (by-pass solenoid valve
for refrigerant pump)

i Return with <Stop>.

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en | 34 | ACS 810 | Component test

14.5 Counter 14.7 Draining oil

Displays the following information:
$ Prepared refrigerant i This function opens the solenoid valve EV7 and
$ ACS 810 operating hours, drains the pressure in the compressor. This enables
$ Vacuum pump operating hours the solenoid valve EV7 to be serviced.

i This function displays the total number of
operations performed with the ACS 810 since
initial commissioning.
! Follow the additional 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 1515 and confirm with E .
4. Select "COUNTERS " with o u and confirm with E .
i Return with <Stop>.
14.6 Service printout
i This function allows you to print out a service
report containing important information about the
A/C services carried out.
! Follow the additional ACS 810 menu prompting.
1. Call up the start screen.
2. Press <3> and <Flush> simultaneously and release.
? The message ENTER CODE 0000 is displayed.
3. Enter 1515 and confirm with E .
4. Select "OIL DRAIN PROGRESS " with o u and
confirm with E .
i Return with <Stop>.
? EV7 appears on the display.
$ Select <MENU> to open EV7.
$ Leave EV7 open until there is no more pressure
in the compressor.
$ Select <STOP> to close EV7 and perform the
maintenance tasks on the solenoid valve.

! Follow the additional ACS 810 menu prompting.

1. Call up the start screen.

2. Press <3> and <Flush> simultaneously and release.
? 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 used)

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 Changing basic settings | ACS 810 | 35 | en

15. Changing basic settings 1. Call up the start screen.

i The set values guarantee that the ACS 810 will
function perfectly. These parameters may only be
changed by an A/C service unit engineer and after
approval from the manufacturer.
2. Press <3> and <Flush> simultaneously and release.
? The message ENTER CODE 0000 is displayed.
3. Enter 5599 and confirm with E .
4. Select the relevant parameter with o u and
confirm with E .

! Follow the additional ACS 810 menu prompting. i Return with <Stop>.

Parameter Actions Default Parameter Actions Default

P1 System pressure empty. 1700 T16 Maximum time for the flushing 15
Absolute pressure value above which process.
recovery begins. If this time is exceeded, the function is
P2 Pressure at end of recovery. 600 ended and the process continues.
Absolute pressure value above which T20 Vacuum test time for flushing 120
recovery ends. operation.
P3 Vacuum test pressure. 300 Time in seconds for the vacuum test
Absolute pressure value after which duration in the flushing function.
the vacuum test turns out to be T21 EV7 oil outlet open duration. 240
negative. Time in seconds for which the solenoid
T1 Vacuum pump oil change threshold. 30 valve EV7 remains open during the oil
Number of hours before a prompt to outlet function.
change the vacuum pump oil appears W1 Combo filter replacement threshold. 150
on the display. Value in kilograms before a prompt to
T2 Time for automatic emptying. 140 replace the combo filter appears on
Value in seconds for duration of the display.
automatic emptying. W6 Max. capacity of small bottle. 10000
T3 Maximum time for recovery. 120 Value in grams that represents the
If this time is exceeded, the function maximum quantity for filling the small
is aborted and the message "LONG internal refrigerant cylinder.
EXTRACTION TIME" appears on the W8 Max. capacity of large bottle. 35000
display. Value in grams that represents the
T4 Weight variation monitoring threshold 60 maximum quantity for filling the large
Time in seconds in which the weight internal refrigerant cylinder.
(recovered quantity) must change HOSE Minimum time for cleaning the service 90
during recovery, otherwise the CLEANING hoses. This is the minimum value in
operation is aborted. TIME seconds for emptying the service hoses
T5 Oil outlet time. Time in minutes for the 5 after filling.
oil drainage duration. CONTROL Activates and deactivates the "Save 0 (off)
T7 Specified time for vacuum. The 60 REPORT data via ACUSB PC interface" function.
mean time recommended by car COMPEN- Activates and deactivates the 0 (off)
manufacturers is 20 minutes. SATION "Compensation at 0 in filling phase"
T8 Not used. – AT 0 function (i.e. compensation is
deactivated).
T9 Vacuum test duration. 300
Time for checking any pressure BYPASS Activates and deactivates the "Bypass" 0 (off)
increase after the vacuum function has function. If this function is activated,
been executed. the MENU key skips the waiting times
for the main ACS 810 functions.
T10 Recycling plus vacuum time. 10000
Time in minutes for the duration of the ECOLD Konfiguration Leiterplatte. 1
recycling plus vacuum function. 2006 Wert muss "1" betragen.
T13 Maximum time for the filling process. 50 RENAULT Mode required by Renault. 0 (off)
If this time is exceeded, the function CONFIG The times between two recoveries are
is aborted and the message "FILLING extended. This mode can be activated
INCOMPLETE" appears on the display. or deactivated as required
BACKUP See section "Data Backup". –

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en | 36 | ACS 810 | Software
16. Software
16.1 Vehicle database
i The vehicle database can be updated annually
using a PS2 stick. Further information can be
obtained from customer service.
! Do not switch off ACS 810 during update process.
! Follow the additional ACS 810 menu prompting.
1. Call up the start screen.
2. Press <3> and <Flush> simultaneously and release.
? The message ENTER CODE 0000 is displayed.
3. Enter 2222 and confirm with E .
4. Select "DATABASE UPDATE" 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.
6. Insert PS2 stick.
7. Activate or deactivate with o u and confirm with
E.
? The update is performed.
" Data base is updated.
i Return with <Stop>.
16.2 Data backup
i This function enables you to save ACS 810
configuration data before a software update. A data
backup avoids the need to recalibrate the ACS 810
after a software update.
! Do not turn off the ACS 810 while saving.
! Follow the additional ACS 810 menu prompting.
1. Call up the start screen.
2. Press <3> and <Flush> 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.
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! 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 stick will be deleted.
8. After the backup, remove the stick.
" The data is saved.
16.3 Software update
i The software is updated using a PS2 stick. Before
updating, perform a data backup (see section 16.2)
so that the calibration data and settings for the
ACS 810 will not be lost.
1. Turn off the ACS 810.
2. Insert the "System Software" PS2 stick.
3. Press and hold the <MENU> key.
4. Turn on the ACS 810 and release the <MENU> key.
5. The ACS 810 turns itself off after programming.
6. Remove the PS2 stick.
7. Turn on the ACS 810.
16.4 Loading a data backup
i The calibration data previously saved (section 16.2)
can be reinstalled after the software update.
1. Turn off the ACS 810.
2. Insert the "Data Backup" PS2 stick.
3. Press and hold the <MENU> key.
4. Turn on the ACS 810 and release the <MENU> key.
5. After recovery of the data, remove the PS2 stick
and attach the plastic cover.
6. Check the calibration data.
Robert Bosch GmbH
 Circuit diagram | ACS 810 | 37 | en

17. Circuit diagram

17.1 Control PCB

Fig. 7: Control PCB

Fig. 8: Control PCB

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en | 38 | ACS 810 | Circuit diagram

17.2 Computer printed circuit board

9
CPU

1
8

TANK
CPU-1

PRN
IN OIL
7 4
PROGRAM

OUT OIL PRESSURE

6
5
RS-232

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)

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Robert Bosch GmbH
Automotive Service Solutions
Franz-Oechsle-Straße 4 www.boschaftermarket.com
73207 Plochingen
DEUTSCHLAND
bosch.prueftechnik@bosch.com

http://www.downloads.bosch-automotive.com

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