En Repair Instruction A/C Service Unit

ACS 511
en Repair instruction
A/C Service Unit
en 2 | ACS 511 |
Contents 9. Troubleshooting 23
9.1 Service messages 23
1. Symbols used 3 9.2 Fault messages 23
1.1 In the documentation 3
1.1.1 Warning notices - 10. Emptying the ACS 511 24
Structure and meaning 3 10.1 Automatic emptying 24
1.1.2 Symbols in this documentation 3 10.2 Extraction of internal refrigerant circuit with sec-
1.2 On the product 3 ond A/C service unit 24
2. Important information 4 11. TROUBLESHOOTING AND ANALYSIS 25

11.1 Faults during recovery 25
3. Test equipment and auxiliary materials 4 11.1.1 Compressor starts 25
11.1.2 Compressor does not start 25
4. Safety regulations 5 11.1.3 Fault messages that can occur during
4.1 Handling refrigerant R134a 5 recovery 26
4.2 Handling UV dye 5 11.1.4 Other fault messages 26
4.3 Working on the vehicle 5 11.2 Faults during the vacuum phase 26
4.4 Notes on operation 6 11.2.1 The vacuum pump starts 26
4.5 Maintenance work 6 11.2.2 The vacuum pump does not start 26
4.6 Safety devices 6 11.2.3 Fault message that can occur during the
vacuum phase 27
5. Description of unit 7 11.3 Faults during refrigerant preparation 27
5.1 ACS 511 7 11.4 Non-condensing gases are not drained 27
5.2 Display and control panel 8 11.5 Faults during filling with refrigerant 27
5.3 Selection and function keys 8 11.5.1 Vehicle air conditioning system cannot be
5.4 Input keys 8 filled 27
11.5.2 Other fault messages 27
6. Program structure 9
6.1 Calibration and tare 9 12. Component test and maintenance 28
6.2 Settings 9 12.1 Vacuum pump 28
6.3 Repair 9 12.2 Pressure sensor P1 28
6.4 Vehicle and customer data 9 12.3 Pressure switch P2 28
6.5 Menu 9 12.4 Expansion valve 28
6.6 Manual mode 9 12.5 Combo filter 29
6.7 Automatic mode 9 12.5.1 Replacement of combo filter 29
6.8 Flushing (optional) 9 12.5.2 Resetting the replacement interval 29
6.9 Enter 9 12.6 Vacuum pump 30
12.6.1 Changing vacuum pump oil 30
7. Hydraulics diagram 10 12.6.2 Reset of oil change interval 30
8. Service phases 11 13. Calibration 31

8.1 Recovery 11 13.1 Internal refrigerant cylinder scales 31
8.2 Draining oil into the used oil bottle 13 13.2 Fresh oil bottle scales 31
8.3 Vacuum phase and recycling 13.4 Tara values 32
(simultaneous) 14 13.3 Used oil bottle scales 32
8.4 Leak test 16 13.5 Pressure sensor 33
8.5 Refrigerant preparation 17 13.5.1 Checking the adjustment 33
8.6 Fresh oil filling 18 13.5.2 Adjusting the pressure sensor 33
8.7 UV contrast medium filling 19
8.8 Filling refrigerant 20
8.9 Separating and returning compressor oil 21
8.10 Non-condensing gases 22
1 689 975 252 | 2016-08-24 Robert Bosch GmbH

Symbols used | ACS 511 | 3 en
14. Component test 34 1. Symbols used

14.1 LCD 34
14.2 Outputs 34 1.1 In the documentation
14.3 Control PCB input signal 34 1.1.1 Warning notices -
14.4 Printer 34 Structure and meaning
14.5 Counter 35 Warning notices warn of dangers to the user or people
14.6 Service printout 35 in the vicinity. Warning notices also indicate the con-
14.7 Draining oil 35 sequences of the hazard as well as preventive action.
Warning notices have the following structure:
15. Changing basic settings 36
Warning
symbol KEY WORD – Nature and source of hazard!
16. Software 37 Consequences of hazard in the event of fail-
16.1 Vehicle database 37 ure to observe action and information given.
16.2 Data backup 37 ¶¶ Hazard prevention action and information.
16.3 Software update 37
16.4 Loading a data backup 37 The key word indicates the likelihood of occurrence and
the severity of the hazard in the event of non-observance:
17. Circuit diagram 38
17.1 Control PCB 38 Key word Probability of Severity of danger if in-
occurrence structions not observed
17.2 Computer printed circuit board 39
DANGER Immediate impend- Death or severe injury
17.3 Circuit diagram ACS 511 40
ing danger
WARNING Possible impending Death or severe injury
danger
CAUTION Possible dangerous Minor injury
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 steps.
2. operation
One-step Instruction consisting of one step.
e
operation
Intermediate An instruction produces a visible inter-

result mediate result.
Final result There is a visible final result on com-
"
pletion 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.
Robert Bosch GmbH 1 689 975 252 | 2016-08-24

en 4 | ACS 511 | Important information
2. Important information 3. 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 RR General tools for electricians and A/C mechanics
units are opened or modified by unauthorized persons, RR Digital multimeter (e.g. MMD 003)
any warranty claims become void. RR Loctite 542 (for thread seal) and 222 (for thread
lock)
Electrical systems and devices must only be put into RR Cleaning agent (e.g. brake cleaner)
operation when in proper operating condition (details RR Calibrating weights 1kg for oil bottle scales
can be found in the EDIS-Info 200108_084). This re- (F 002 DG1 416 or 1 698 100 061)
quirement is met if following modification or repair (ini- RR Calibrating weight 10 - 20 kg for internal refrigerant
tial testing) it is ensured that the requirements of the scales
electrical engineering directives were adhered to. To RR Leak detector (1 689 100 057)
check this, tests should be performed, the nature and RR Simulator (optional)
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.

Safety regulations | ACS 511 | 5 en
4. Safety regulations RR R134a is not to be used in areas in which there is a

danger of explosion. Fire, naked flames and smok-
!!Always carefully read and observe all the safety regu- ing are prohibited. Welding and soldering are not
lations before using the Bosch product. permitted.
RR High temperatures and UV radiation may chemically
¶¶ Wear safety goggles. separate the R134a. The resultant products cause
coughing and nausea.
RR R134a is not to be mixed with other refrigerants.
¶¶ Wear safety gloves. The mixing of refrigerants can damage the vehicle air
conditioning system.
4.2 Handling UV dye

4.1 Handling refrigerant R134a
Never inhale UV dye. The vapors can irritate the
Avoid all skin contact with the refrigerant. eyes, nose and respiratory system. If UV dye
The low boiling point of the refrigerant (ap- comes into contact with the eyes, rinse them
prox. -30 °C) can lead to frostbites. Should thoroughly with water for 15 minutes. Then
it nevertheless come into contact with the obtain medical help even if no pain is felt.
skin, remove any moistened clothing imme-
diately and rinse the affected skin with copi- RR Avoid all skin contact with the UV dye. Should it nev-
ous amounts of water. ertheless come into contact with the skin, remove
any moistened clothing immediately and rinse the
RR R134a is colorless, has a weak intrinsic odor and is affected skin with copious amounts of water.
heavier than air. It displaces oxygen and may flow RR Never swallow UV dye. If swallowed inadvertently,
into repair pits. Should refrigerant escape (malfunc- never attempt to induce vomiting. Drink copious
tion), always ensure adequate ventilation and air amounts of water and obtain medical help.
extraction (especially in pits). Exit the workshop.
4.3 Working on the vehicle
Never inhale refrigerant and oil vapors. The
vapors can irritate the eyes, nose and respi- If high-voltage components or high-voltage
ratory system. If liquid refrigerant comes wires are inexpertly handled, there is a risk of
into contact with the eyes, rinse them thor- fatal injury from high voltages and the possi-
oughly with water for 15 minutes. Then ob- ble transmission of current through the body.
tain medical help even if no pain is felt.
RR De-energization is only to be performed by a quali-
RR Before connecting the ACS 511 to a vehicle air con- fied electrician, a qualified electrician for specific
ditioning system or an external refrigerant cylinder, tasks (hybrid), or a power systems engineer.
make sure the quick-release couplings are not leak- RR Work on vehicles with high-voltage components is
ing. only ever to be performed in a safe, de-energized
RR Only ever use external refrigerant cylinders provided condition by persons with the minimum qualification
with safety valves and certified in line with the ap- "Trained to perform electrical work".
plicable standards. RR Even after deactivating the high-voltage vehicle
RR Before switching off the ACS 511, make sure all fill- electrical system, the high-voltage battery may still
ing and drainage operations have been completed. be live.
This prevents refrigerant escaping into the environ- RR The operating condition cannot be established from
ment. any running noise, as the electric machine is silent
when stationary.
Do not use compressed air with R134a. RR In gear positions "P" and "N" the engine or electric
Some air mixtures with R134a are highly motor may start spontaneously depending on the
flammable. Such mixtures are a potential charge of the high-voltage battery.
hazard and may lead to fire or explosions RR Never open or damage high-voltage batteries.
and thus cause damage or injury. RR On accident vehicles, never touch high-voltage com-
ponents or exposed high-voltage wires before deacti-
RR Refrigerant extracted from a vehicle air conditioning vating the high-voltage vehicle electrical system
system may be contaminated with moisture, lubri-
cant, dirt and traces of other gases.

en 6 | ACS 511 | Important information
4.4 Notes on operation 4.5 Maintenance work

RR Never perform any maintenance work which is not
!!Observe the pertinent legal regulations or directives expressly recommended in this manual. Contact
to ensure safe handling of pressurized devices. customer service if components have to be replaced
other than in the course of maintenance work.
RR The ACS 511 must be operated in an environment RR We recommend calibrating the internal refrigerant
corresponding to the directive BGR 157 with respect scales at least once per year. Please contact cus-
to the exchange of air. tomer service.
RR Observe local laws or directives so as to ensure the
safety of the pressurized device. The ACS 511 must 4.6 Safety devices
be constantly monitored when in operation. Never
leave the ACS 511 unattended when in operation. !!For safety reasons it is advisable to use a residual
RR Position the ACS 511 on all four wheels on a flat, current operated circuit breaker (rccb) with the fol-
vibration-proof surface such that proper operation of lowing specifications:
the scales is guaranteed.
RR The ACS 511 can be secured in position by locking Parameters Specification
the brake. Rated voltage 230 VAC ± 10 %

RR The ACS 511 must always be transported in its oper- Rated frequency 50/60 Hz
ating position. Never lay the ACS 511 on its side, as Rated current 230 VAC 10 A
Rated tripping current 30 mA
oil could then escape from the vacuum pump, or the
Tripping switch C
built-in compressor could be damaged.
RR There are no additional safety systems for protecting Overview of safety devices:
the ACS 511 against damage resulting from natural
catastrophes. Description Operation
RR ACS 511 must be connected to a properly grounded Pressure switch Switches the compressor off if the normal
operating pressure is exceeded.
electrical connection.
Safety valve The safety valve opens if the design pres-
RR The vehicle A/C service using the ACS 511 must be sure is exceeded.
prepared and implemented such that the vehicle Fuse Interrupts the power supply to ACS 511 in
air conditioning system circuit does not have to be the event of too high current.
opened (for example by removing the radiator or Vents The ACS 511 is provided with vents in the
bottom of the housing to ensure the ex-
engine).
change of air even when switched off.
RR Never remove any components from inside the
ACS 511 except for maintenance or repair purposes.
RR If damage to the ACS 511 is established, terminate
usage immediately and contact customer service.
RR The service hoses and quick-release couplings must
be regularly checked for wear and replaced if dam-
aged.

Description of unit | ACS 511 | 7 en
5. Description of unit
5.1 ACS 511
5 7
4
6
3 6
7 1
2
2
1
8
3
9
10
4
11
5
12
Fig. 1: Front view Fig. 2: Rear view

1 High pressure valve 1 Service quick-release coupling (high pressure)
2 Low pressure valve 2 Service quick-release coupling (low pressure)
3 Printer 3 Service hoses
4 Display and control panel 4 Service hose mount
5 Low pressure gage (LP) 5 Rear wheels
6 High pressure gage (HP) 6 Power cord
7 Internal refrigerant cylinder pressure gage 7 Master switch
8 Fresh oil bottle
9 UV dye bottle
10 Used oil bottle
11 Cover
12 Front wheels with locking brake

en 8 | ACS 511 | Description of unit
5.2 Display and control panel 5.3 Selection and function keys
Keys Name Operation
6 Refrigerant is evacuated from the

Extraction
vehicle.
RR Control up RR Cursor moves up.

RR Vacuum RR A vacuum is generated.
5 7
4 RR Control RR Cursor moves to the right.
right RR Vehicle air conditioning system
3 RR Filling is filled with refrigerant.
2
8 RR Control RR Cursor moves to the left.
1 left RR Automatic service run: Air condi-
RR Automatic tioning service is carried out us-
10 9 ing the saved parameters.
RR Control RR Cursor moves down.
Fig. 3: Display and control panel down RR Flush vehicle air conditioning
RR Flushing components.
1 Flushing
2 Automatic service
3 Filling Menu
4 Vacuum
5 Recovery
6 LCD
Database
7 Key panel
8 Vehicle database
9 PS2 stick connection
10 Function lamps (LED) Confirm and apply.
Enter
(Live data)
The high and low pressure gages show the current pres-
sure during the air conditioning service on the vehicle. Stop Cancel and return.
The small pressure gage is used to monitor the internal
cylinder pressure.
Various functions are assigned to the MENU function
The selection and function keys on the control panel key in the ACS 511 software. The functions of the keys
are used to control the menus and the service phases. are defined in the menu bar of the ACS 511 software.
Bosch supplies a PS2 stick for updating the ACS 511 5.4 Input keys
software. If required, the PS2 stick can be inserted in The input keys can be used to enter letters, numbers
the PS2 stick port to update the firmware/software. and special characters in the input boxes.

Program structure | ACS 511 | 9 en
6. Program structure 6.6 Manual mode

Input Menu
6.1 Calibration and tare
SELECT PORTS
Input Menu
TANK CALIBRATION <RECOVERY>
1. + <3> IN OIL CALIBRATION
2. Enter 1111. OUT OIL CALIBRATION RR Automatic emptying
3. Confirm with E. PRES. CALIBRATION RR Extraction
RR Oil drain
TANK TARE
RR Pressure test
IN OIL TARE
OUT OIL TARE Input Menu
SET VACUUM TIME
6.2 Settings
Input Menu <VACUUM>
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
UV DYE Input Menu
DATABASE UPDATE SELECT PORTS
SERIAL NUMBER
EXPERT MODE
<AUTOMATIC>
6.3 Repair
6.8 Flushing (optional)
Input Menu
CHANGE FILTER Input Menu
CHANGE OIL SET VACUUM TIME
1. + <3>
2. Enter 5555.
3. Confirm with E.
<Flush>
6.4 Vehicle and customer data

6.9 Enter
Input Menu 1 Menu 2
STANDARD SPECS EUROPEAN DATABASE Input Menu
TRUCK DATABASE Current filling capacities of fresh
USER SPECS SELECT MODEL : and used oil bottles and the inter-
<Database> nal refrigerant cylinder
DELETE MODEL :
ADD MODEL : Enter
VEHICLE DATAS
6.5 Menu
Input Menu 1 Menu 2
PERFORMANCE TESTS
DIAGNOSTIC
TANK FILLING
<Menu>
TANK RECYCLING
ZEROING OIL SCALES
REPORT MANAGEMENT PRINT REPORT
EXPORT DATA
DELETE DATA

en 10 | ACS 511 | Hydraulics diagram
7. Hydraulics diagram
M2
HIGH
T2
EV3
M1 EV10
LOW EV5 EV6
T1 P1 EV9 EV8 EV1
VU3 VU1 2
M3
11 1 P
12
P2 3 F1
HP
V5 V6
VU2
F2 5
4
V1 V3 V4 V2
10
EV7
6 7
9
C 13
Name Description Name Description Name Description

1 Fresh oil tank EV5 Recovery solenoid valve P1 Pressure sensor
2 Vacuum pump EV6 Filling solenoid valve P2 Pressure switch
3 Expansion valve EV7 Oil drain solenoid valve T1 Low pressure hose
4 Evaporator/oil separator EV8 Oil injection solenoid valve T2 High pressure hose
5 Compressor oil separator EV9 Contrast medium injection sole- V1 Tank vapour side hose valve
6 Compressor noid valve V2 Tank liquid side hose valve
7 Internal refrigerant cylinder EV10 Solenoid valve for separating V3 Tank vapour side valve
high and low pressure
8 Refrigerant cylinder scales V4 Tank liquid side valve
F1 Coarse filter
9 Used oil bottle V5 Safety valve
F2 Combi filter
10 Heat exchanger V6 Non condensable drain valve
HP High pressure
11 UV dye bottle VU1 Oil non-return valve
LP LOw pressure
12 Fresh oil scales VU2 One-way valve
M1 Low pressure gage
13 Used oil scales VU3 UV contrast medium non-return
M2 High pressure gage valve
EV1 Vacuum solenoid valve
M3 Internal refrigerant cylinder pres-
EV3 Flow solenoid valve
sure gage

Service phases | ACS 511 | 11 en
8. Service phases iiThe combo filter (F2) cleans the extracted refriger-
ant of suspended particles and moisture.
iiThis section describes all of the ACS 511 service
phases. In addition, it explains the hydraulic and iiIn the evaporator/oil separator (5), the oil taken in
electric circuits by presenting the hydraulic diagram from the compressor is separated from the refriger-
and providing a brief description of the components ant and fed back to the compressor.
involved in each function.
iiIf the pressure at sensor P1 falls below the value
8.1 Recovery saved in the software, the function stops automati-
cally, the program waits 5 minutes for a pressure
iiIn this service phase, the refrigerant is extracted increase and, if necessary, restarts with a second
from the vehicle air conditioning system. recovery cycle.
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. and EV5 are closed and the compressor 6 is turned off.
2. Open the service quick-release coupling valves.
?? The pressure on the high and low pressure side of
the vehicle air conditioning system is indicated on
the pressure gages M1 and M2.
iiOpening the HP and LP valves on the ACS 511

causes the refrigerant to flow to the solenoid valves
EV10 (open) and EV3 (closed).
iiThe 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.
RR 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).
RR The expansion valve maintains a constant pressure
at the evaporator/oil separator (4).
RR 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.
RR The refrigerant then flows on through the combo fil-
ter (F2) and the compressor (6) into the condenser/
separator (5), and finally into the internal refrigerant
cylinder.

en 12 | ACS 511 | Service phases
M2
HIGH
T2
EV3
M1 EV10
LOW EV5 EV6
T1 P1 EV9 EV8 EV1
VU3 VU1 2
M3
11 1 P
12
P2 3 F1
HP
V5 V6
VU2
F2 5
4
V1 V3 V4 V2
10
EV7
6 7
9
C 13 active

F1 Coarse filter
F2 Combi filter
HP High pressure
LP LOw pressure
sure gage

8.2 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.
oil separator (4) drains into the used oil bottle (9).
M2
HIGH
T2
EV3
M1 EV10
LOW EV5 EV6
T1 P1 EV9 EV8 EV1
VU3 VU1 2
M3
11 1 P
12
P2 3 F1
HP
V5 V6
VU2
F2 5
4
V1 V3 V4 V2
10
EV7
6 7
9
C 13 active

F1 Coarse filter
F2 Combi filter
HP High pressure
LP LOw pressure
sure gage

8.3 Vacuum phase and recycling iiIf the pressure in the vehicle air conditioning system
(simultaneous) is below the set value, the vehicle air conditioning
system is empty and the ACS 511 starts vacuum
iiDuring vacuum generation in the vehicle air condi- generation.
tioning system, the refrigerant is prepared in the
internal refrigerant cylinder to remove the non-con- iiIf the pressure is above the set value, there is still re-
densing gases before filling and to filter the refriger- frigerant in the vehicle air conditioning system, and
ant. it must be extracted before vacuum generation.
1. The ACS 511 is connected to the vehicle with the

service hoses T1 and T2. 3. Press the <Vacuum> key.
2. Open the service quick-release coupling valves. ?? EV1 and EV10 are opened and the vacuum pump
?? The pressure on the high and low pressure side of (2) starts.
the vehicle air conditioning system is indicated on
the pressure gages M1 and M2. iiThe vacuum pump generates a maximum vacuum of
0.05 mbar. This depends on the duration of vacuum
iiOpening the HP and LP valves on the ACS 511 generation.
causes the refrigerant to flow to the pressure sensor
P1 (solenoid valves EV1, EV3, and EV10 are closed). iiThe refrigerant in the internal refrigerant cylinder
P1 checks the pressure in the vehicle air condition- is fed through the internal refrigerant circuit and
ing system (refrigerant present in the vehicle air prepared in each vacuum phase. For further informa-
conditioning system or not). tion, refer to section 9.2.

M2
HIGH
T2
EV3
M1 EV10
LOW EV5 EV6
T1 P1 EV9 EV8 EV1
VU3 VU1 2
M3
11 1 P
12
P2 3 F1
HP
V5 V6
VU2
F2 5
4
V1 V3 V4 V2
10
EV7
6 7
9
C 13 active

F1 Coarse filter
F2 Combi filter
HP High pressure
LP LOw pressure
sure gage

8.4 Leak test iiIf the pressure at P 1 falls below the value saved in
the software during the leak test, an error message
iiThe leak test starts after the vacuum phase. is displayed.
iiThe 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
EV3
M1 EV10
LOW EV5 EV6
T1 P1 EV9 EV8 EV1
VU3 VU1 2
M3
11 1 P
12
P2 3 F1
HP
V5 V6
VU2
F2 5
4
V1 V3 V4 V2
10
EV7
6 7
9
C 13 active

F1 Coarse filter
F2 Combi filter
HP High pressure
LP LOw pressure
sure gage

8.5 Refrigerant preparation iiInternal 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. vehicle air conditioning system.
""ACS 511 starts internal preparation of the refriger-
ant.
""EV5 and EV6 are opened and the compressor (6)
starts.
M2
HIGH
T2
EV3
M1 EV10
LOW EV5 EV6
T1 P1 EV9 EV8 EV1
VU3 VU1 2
M3
11 1 P
12
P2 3 F1
HP
V5 V6
VU2
F2 5
4
V1 V3 V4 V2
10
EV7
6 7
9
C 13 active

F1 Coarse filter
F2 Combi filter
HP High pressure
LP LOw pressure
sure gage

8.6 Fresh oil filling iiIf "Fresh oil filling" has been selected in the service
process, the quantity of fresh oil entered is fed into
iiBy 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.
form the individual operation selected.
iiThe filling quantity is checked by the scales (12),
iiOil from the fresh oil bottle is used to top up the which ends the filling process after the quantity pre-
vehicle air conditioning system compressor oil. viously entered in the service process.
iiEV8 opens and the fresh oil (1) is fed into the vehicle
M2 air conditioning system with the refrigerant.
HIGH
T2
EV3
M1 EV10
LOW EV5 EV6
T1 P1 EV9 EV8 EV1
VU3 VU1 2
M3
11 1 P
12
P2 3 F1
HP
V5 V6
VU2
F2 5
4
V1 V3 V4 V2
10
EV7
6 7
9
C 13 active

F1 Coarse filter
F2 Combi filter
HP High pressure
LP LOw pressure
sure gage

8.7 UV contrast medium filling iiIf "UV contrast medium filling" has been selected in
the service process, a defined quantity (time con-
iiBy 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.
form the individual operation selected.
iiEV9 opens and the UV contrast medium (11) is fed
iiThe vehicle air conditioning system is partly filled into the vehicle air conditioning system with the
with UV contrast medium to facilitate detection of refrigerant.
leaks in the event of damage to the vehicle air condi-
tioning system.
M2
HIGH
T2
EV3
M1 EV10
LOW EV5 EV6
T1 P1 EV9 EV8 EV1
VU3 VU1 2
M3
11 1 P
12
P2 3 F1
HP
V5 V6
VU2
F2 5
4
V1 V3 V4 V2
10
EV7
6 7
9
C 13 active

F1 Coarse filter
F2 Combi filter
HP High pressure
LP LOw pressure
sure gage

8.8 Filling refrigerant iiOpen EV3 and EV6.

Refrigerant flows from the internal refrigerant cylin-
iiThe refrigerant in the internal refrigerant cylinder is der through valves V4 and V2, through the solenoid
used for filling the vehicle air conditioning system. valves EV6 and EV3, the HP valve (when filling on the
high pressure side) and along the service hose T 2
iiRefrigerant can only be added to a vehicle air condi- into the vehicle air conditioning system.
tioning system under a vacuum. The vacuum phase
must therefore be performed before filling. iiThe filling quantity is checked by the scales (8),
which end the filling process after the quantity previ-
ously entered in the service process.
M2
HIGH
T2
EV3
M1 EV10
LOW EV5 EV6
T1 P1 EV9 EV8 EV1
VU3 VU1 2
M3
11 1 P
12
P2 3 F1
HP
V5 V6
VU2
F2 5
4
V1 V3 V4 V2
10
EV7
6 7
9
C 13 active

F1 Coarse filter
F2 Combi filter
HP High pressure
LP LOw pressure
sure gage

8.9 Separating and returning compressor iiThis oil is separated from the refrigerant in the com-
oil pressor oil separator (5) and is then fed back to the
compressor (6).
iiDuring the recovery phase and preparation of the
refrigerant, small quantities of compressor oil get
into the internal circuit.
M2
HIGH
T2
EV3
M1 EV10
LOW EV5 EV6
T1 P1 EV9 EV8 EV1
VU3 VU1 2
M3
11 1 P
12
P2 3 F1
HP
V5 V6
VU2
F2 5
4
V1 V3 V4 V2
10
EV7
6 7
9
C 13 active

F1 Coarse filter
F2 Combi filter
HP High pressure
LP LOw pressure
sure gage

8.10 Non-condensing gases iiThe pressure of the internal refrigerant cylinder in-
creases during the recovery phase and when prepar-
iiThe drain valve (V5) for non-condensing gases opens ing the refrigerant.
if the pressure in the refrigerant cylinder is higher
than the set opening pressure (normally between 12 iiThe safety valve (V 6) opens at a factory set pressure
and 14 bar). (approx. 20 bar) to limit the pressure in the internal
refrigerant cylinder.
M2
HIGH
T2
EV3
M1 EV10
LOW EV5 EV6
T1 P1 EV9 EV8 EV1
VU3 VU1 2
M3
11 1 P
12
P2 3 F1
HP
V5 V6
VU2
F2 5
4
V1 V3 V4 V2
10
EV7
6 7
9
C 13 active

F1 Coarse filter
F2 Combi filter
HP High pressure
LP LOw pressure
sure gage

Troubleshooting | ACS 511 | 23 en
9. Troubleshooting
9.1 Service messages
Service message Actions
CHANGE OIL Change vacuum pump oil.
REPLACE FILTER Replace combo filter
(see section 7.3)
9.2 Fault messages

failure indication 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.
ZEROING OIL SCALES Error in the scale settings.
Tare the scales.
HIGH RECOVERY TIME RR The recovery time exceeds the safe maximum duration set.
RR Check vehicle air conditioning system for leaks.
RR Check pressure in internal refrigerant cylinder.
RR If no leaks are detected, apply to the Technical Service.
A/C SYSTEM EMPTY There is no refrigerant in the vehicle air conditioning system.
OUTOIL BOTTLE FULL CALIBRATE SCALE The used oil bottle is full and must be emptied.
OIL IN BOTTLE EMPTY FILL BOTTLE The fresh oil bottle is empty and must be refilled.
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.
CHARGING OIL TIME HIGH The fresh oil filling time exceeds the safe maximum duration set.
There is no vacuum in the vehicle air conditioning system.
Generate vacuum first.

en 24 | ACS 511 | Emptying the ACS 511
10. Emptying the ACS 511 10.2 Extraction of internal refrigerant cir-
cuit with second A/C service unit
!!When repairing internal components, we recommend
extracting the internal hoses on the ACS 511 to iiIf recovery cannot be performed due to a defective
ensure that no refrigerant can escape when the hose compressor, a second A/C service unit or an external
lines are opened. compressor is required to remove the refrigerant
from the internal refrigerant circuit. To do this, start
iiThis extraction is carried out by automatic emptying the "Recycle" function to open the corresponding
or, if there is a technical defect, by using a second solenoid valves.
A/C service unit.
iiThe compressor power supply for the ACS 511 must
Warning – Risk of frostbite from escaping be disconnected before extraction.
refrigerant
Refrigerant causes severe frostbite on the 1. Close shutoff valves V1, V3, V2, and V4 on the re-
skin. frigerant cylinder and disconnect the blue and red
¶¶ Check the service hoses for damage. hoses from the refrigerant cylinder.
¶¶ Firmly connect the service quick-release 2. Connect the blue hose to the low pressure side of
couplings to the service hoses. the second A/C service unit.
¶¶ Wear safety goggles. 3. Connect the red hose to the high pressure side of
¶¶ Wear protective gloves. the second A/C service unit.
4. Open the valves V1 and V2.
10.1 Automatic emptying 5. Open both valves on the second A/C service unit and
recover the refrigerant from the first, defective A/C
iiRefrigerant in the internal hoses is extracted into the service unit.
internal refrigerant cylinder. ?? A pressure increase test is performed at the end
of recovery.
1. Service hoses (T1, T2) are not connected to the 6. Close the two valves on the second A/C service
vehicle. unit and disconnect the hoses from the refrigerant
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.

TROUBLESHOOTING AND ANALYSIS | ACS 511 | 25 en
11. TROUBLESHOOTING AND If the pressure at the pressure gages falls slowly:
ANALYSIS 1. Check filter (F 1).
If clogged, clean with compressed air (blow out).
2. Check function of valve VU2.
iiThis section briefly describes the various faults, and 3. Valves V1 and V3 must be open.
the components that can cause the faults. 4. Check expansion valve (3) with a pressure gage. Op-
erating pressure must be between 2 and 2.3 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.
11.1 Faults during recovery 1. Valves V1, V2, V3, and V4 must be open.
11.1.1 Compressor starts 2. HP and LP valves must be open.
3. Check that pressure sensor (P1) functions properly.
iiEV3 and EV5 are closed for automatic self-cleaning.
The pressure at the pressure gages may not change. 11.1.2 Compressor does not start
1. Check fuses F 2 and F 3 (T 12.5 A) on control PCB.
1. Service hoses (T1, T2) are not connected to the 2. Check whether 12 Volt (DC) is applied at the com-
vehicle. pressor relay coil.
2. Close service quick-release couplings. 3. Check whether the compressor relay trips after
3. Open HP and LP valves on the ACS 511. pressing the recovery key. It may be necessary to
replace the keypad or the control card.
iiIf the pressure at the pressure gages decreases dur- 4. Check whether 230 Volt is applied at the compressor
ing self cleaning, check whether EV3 and EV5 are relay output pins.
supplied with power. ?? If no voltage is applied, the computer PCB is de-
fective and must be replaced.
Power applied: ?? If voltage is applied, the current consumption
?? Computer PCB (control PCB) defective. must be measured.
""Replace computer PCB (control PCB). 5. Measure current consumption. At 0 A or >=6 A the
compressor must be replaced.
No voltage applied:
?? Solenoid valve leaking.
""Clean or replace solenoid valve.
iiIf the pressure at the pressure gages does not de-

crease 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).

en 26 | ACS 511 | TROUBLESHOOTING AND ANALYSIS
11.1.3 Fault messages that can occur during recovery 11.2 Faults during the vacuum phase
11.2.1 The vacuum pump starts
"CYLINDER FULL"
iiThe vacuum pump starts but no vacuum is generated
iiCheck the weight of the internal refrigerant cylinder in the vehicle air conditioning system
and reduce the quantity of refrigerant in the internal
refrigerant cylinder. 1. Disconnect service hoses from vehicle.
2. Open HP and LP valves.
"PRESSURE VALVE TOO HIGH" 3. Check whether the hose connected to the vacuum
1. Valves V1, V2, V3, and V4 must be open. pump is correctly connected at both ends and is not
2. Check contacts for pressure switch (P2). clogged.
4. Check the oil level in the vacuum pump.
iiIf the pressure is below 14.5 bar, voltage must be
present between pin 1 and pin 2, while pin 1 and iiThe oil level should be in the middle of the sight
pin 4 are open. glass between the "full" and "empty" marks.
iiIf the pressure is above 14,5 bar, the contacts 5. Check the pump vacuum output (the pressure must
between pin 1 and pin 2 open, while the pin 1 and fall to less than 0.05 mbar within 3 minutes).
pin 4 contacts close. 6. If a vacuum of less than 0.05 bar is reached:
Check whether voltage is present at EV1 and EV10.
?? If the pressure switch (P2) does not work in this 7. Valves EV8 and EV9 must not leak.
way, replace it. 8. Check whether EV1 switches
?? If the pressure switch is working correctly, check ?? If voltage is present and EV1 switches, replace the
the wiring and the control PCB. vacuum pump.
¶¶ Check the pump vacuum output (the pressure must
iiIf no fault can be identified with the pressure switch fall to less than 0.05 mbar within 3 minutes).
(P2), the line to the internal refrigerant cylinder
must be checked for clogging and the valve VU2 for 11.2.2 The vacuum pump does not start
clear passage. 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).
11.1.4 Other fault messages 3. Check fuses F 2 and F 3 (12.5 A) on the control PCB.
Please see chapter 8.2 4. Check whether the relay trips after pressing the
vacuum key.
5. Check whether the vacuum pump is being supplied
with power (230 Volt).
iiA voltage of 12 Volt (DC) must be present at the

pump relay coil; 230 Volt must be present at the out-
put contacts. If one of these voltages is not present,
the computer PCB must be replaced.
""Replace the vacuum pump if it does not start.

TROUBLESHOOTING AND ANALYSIS | ACS 511 | 27 en
11.2.3 Fault message that can occur during the vacu- 11.5 Faults during filling with refrigerant
um phase
11.5.1 Vehicle air conditioning system cannot be
"A/C SYSTEM FULL" filled
1. Check hose connections on the internal refrigerant
¶¶ Check the pressure at the pressure gages M 1 and M 2. cylinder.
?? Pressure above 0.3 bar, perform recovery. 2. Valves V1, V2, V3 and V4 must be open.
?? Pressure below 0.3 bar, adjust pressure sensor P 1. 3. HP and LP valves must be open.
""If the message is still displayed, replace the pressure 4. Check the calibration of the scales.
sensor.
""If the message is still displayed, replace the com- iiEnsure that the refrigerant scales are not blocked.
puter PCB.
iiYou must ensure that the control PCB applies the set
11.3 Faults during refrigerant preparation weight value; if not, check whether the refrigerant
cylinder contains sufficient refrigerant for the filling
1. Check hose connections on the internal refrigerant process.
cylinder.
2. Valves V1, V2, V3 and V4 must be open. iiCheck whether EV6 and EV3 are supplied with
3. Check EV7 for leaks. power. If so, they must be replaced. If they are not
4. Check filter F 1 for impurities and clean with com- supplied, the connecting cables and the control PCB
pressed air. must be checked.
5. Check function of valve VU2
6. Check the expansion valve (3) for the correct pres- 11.5.2 Other fault messages
sure value (2 - 2.3 bar). Please see chapter 8.2
7. Check whether the internal refrigerant circuit is
soiled or clogged.
iiIf the compressor does not start, make sure that a

supply voltage is connected to the compressor. If no
voltage is applied, check the supply leads and the
switching operation of the compressor relay.
11.4 Non-condensing gases are not drai-

ned
¶¶ Mechanically test drain valve V6.

en 28 | ACS 511 | Component test and maintenance
12. Component test and main- 12.3 Pressure switch P2

tenance
iiThe 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 14.5 bar.
!!The vacuum pump oil must always be changed after To check the pressure switch, carry out the following
10 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 250 ml
3. Close both valves on the refrigerant cylinder.
Output 70 l/min.
4. Remove the blue hose from the internal refrigerant
Max. vacuum 0.05 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 14.5 bar, recovery
iiThe 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 cylin-
2. Attach pressure gage to intake connection. der by opening the high pressure valve.
3. Start vacuum generation
""A vacuum of 0.05 mbar must be achieved. iiWhen 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 (+).
iiThe expansion valve is a pressure control valve that
iiIf no voltage is present, check the control PCB and is set to a value between 2 and 2.3 bar and main-
replace if necessary. tains a constant pressure before the oil separator.
2. Check whether an output signal is present between !!The refrigerant cylinder must contain at least 4 kg of
pin 1 (-) and pin 3 (+). refrigerant.
iiThe output signal is between 0 V and 10 Volt, i.e. 1. Connect the low pressure hose to the connection
1.0 Volt corresponds to 1.6 bar. If the pressure gage after the expansion valve using the adapter supplied.
shows 3 bar relative (4 bar absolute), the voltage 2. Close HP and LP valves.
must be 2.5 Volt. 3. Start the recycling function.
""After around 10 minutes, the pressure value must be
iiWhen replacing the pressure sensor, a special thread between 2 and 2.3 bar.
sealant (e.g. Loctite 577) must be used.

Component test and maintenance | ACS 511 | 29 en
12.5 Combo filter iiMake sure the old sealing rings are removed before
12.5.1 Replacement of combo filter attaching the new combo filter.
Warning – Risk of frostbite from escaping !!When installing a new combo filter, make sure that
refrigerant the seals are positioned correctly.
Refrigerant causes severe frostbite on the
skin. !!Take care not to damage any hoses or electrical con-
¶¶ Check the service hoses for damage. nections when replacing the combo filter.
¶¶ Firmly connect the service quick-release
couplings to the service hoses. !!Never re-use an old combo filter.
¶¶ Wear safety goggles.
¶¶ Wear protective gloves. 7. Close the housing.
""The combo filter has been replaced.
iiAfter 50 of refrigerant has been prepared using the
combo filter, the message "CHANGE FILTER" ap- iiReturn with <Stop>.
pears on the display.
iiThe operating instructions recommend having the 12.5.2 Resetting the replacement interval
combo filter replaced by customer service.
!!Follow the additional ACS 511 menu prompting.
1. Call up the start screen.
1. Call up the start screen. 2. Press <3> and <Flush> simultaneously and release.
2. Press <Recovery>. ?? The message ENTER CODE 0000 is displayed.
?? SELECT PORTS? 3. Enter 5555 and confirm with E .
1 HP & LP PORTS 4. Select "CHANGE FILTER" with o u and confirm
2 HP PORT with E .
3 LP PORT ?? The current quantity (in kg) of filtered refrigerant
3. Select <1>,<2> or <3>; confirm with E. is displayed.
""ACS 511 performs a self-cleaning process, then the 5. Press <MENU> until filtered refrigerant quantity is
recovery phase. reset to zero.
""The filter replacement interval is reset.
iiPressure gage must reach 0 bars.
iiReturn with <Stop>.
4. Disconnect the ACS 511 from the power supply.
5. Carefully open the ACS 511 housing.
6. Replace the combo filter.
Fig. 4: Replacement of combo filter

en 30 | ACS 511 | Component test and maintenance
12.6 Vacuum pump 12.6.2 Reset of oil change interval

12.6.1 Changing vacuum pump oil
Attention – Risk of burns from hot sur-
faces 1. Call up the start screen.
Contact with the hot vacuum pump surface 2. Press <3> and <Flush> simultaneously and release.
will cause severe burns. ?? The message ENTER CODE 0000 is displayed.
¶¶ Allow the vacuum pump to cool down. 3. Enter 5555 and confirm with E .
¶¶ Wear protective gloves. 4. Select "CHANGE OIL" with o u and confirm with E .
?? Current runtime of vacuum pump is displayed.
iiThe vacuum pump oil must always be changed 5. Press <MENU> until vacuum pump runtime is set to
after 50 hours of operation. The message zero.
"REPLACE OIL" is displayed when the vacuum ""Oil change interval is reset.
pump oil needs changing.
iiUse the vacuum pump oil (item number
SP00100086) as specified by Bosch.
3
Fig. 5: Vacuum pump
1 Sight glass
2 OIl fill plug
3 Drain plug
!!Do not use excessive force when securing and re-

moving the oil drain and oil filling screw.
iiThe 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).
iiThe oil level should be in the middle between the

"full" and "empty" marks.

Calibration | ACS 511 | 31 en
13. Calibration 13.2 Fresh oil bottle scales
13.1 Internal refrigerant cylinder scales iiAccording to the display, the calibration weight must
be entered in ml. However, we recommend enter-
iiDetach the rear panel and remove the refrigerant ing the weight in grams. Because of the density of
cylinder from the scales. 1.0 kg/m³ 250 g corresponds to a value of 250 ml.
iiIt is not necessary to detach the lines from the refrig- 1. Call up the start screen.
erant cylinder. If you want to detach the hoses, close 2. Press <3> and <Flush> simultaneously and release.
the valves on the hoses and on the cylinder. ?? The message ENTER CODE 0000 is displayed.
3. Enter the value 1111 and confirm with E.
1. Call up the start screen. 4. Select "IN OIL CALIBRATION" and confirm with E .
2. Press <3> and <Flush> simultaneously and release. ?? The display shows
?? The message ENTER CODE 0000 is displayed. ZERO CALIBRATION.
3. Enter the value 1111 and confirm with E. 5. Remove the fresh oil bottle
4. Select "TANK CALIBRATION" and confirm with 6. Enter the figure 00.00 and confirm with E.
ENTER. ?? The display shows
?? The display shows WEIGHT CALIBRATION.
ZERO CALIBRATION. 7. Attach the calibrating weight
5. With an empty weighing plate, enter the figure 00.00 8. Enter the calibration weight value and confirm with
and confirm with E . E.
?? The display shows ""The menu containing the functions appears on the
WEIGHT CALIBRATION. display again.
6. Place the calibration weight on the weighing tray (a
value of between 10 kg and 20 kg is recommended). iiReturn with <Stop>.
7. Enter the calibration weight value and confirm with
E. iiThe fresh oil scales can also be calibrated without a
""The menu containing the functions appears on the calibration weight by filling the fresh oil bottle with
display again. oil and entering the exact measured total weight of
the fresh oil bottle.

en 32 | ACS 511 | Calibration
13.3 Used oil bottle scales 13.4 Tara values

The following Tara values for the Internal refrigerant cyl-
iiAccording to the display, the calibration weight must inder and oil bottles are set from the factory (The value
be entered in ml. However, we recommend enter- is also written on the tank):
ing the weight in grams. Because of the density of
1.0 kg/m³ 250 g corresponds to a value of 250 ml. Internal refrigerant cylinder:
ACS 511 = 6,5 kg
2. Press <3> and <Flush> simultaneously and release. Oil bottles:
?? The message ENTER CODE 0000 is displayed. Fresh oil bottle = 70 g
3. Enter the value 1111 and confirm with E. Used oil bottle = 60 g
4. Select "OUT OIL CALIBRATION" and confirm with
E . Setting tara value:
?? The display shows 1. Select the Tara value (Tara Internal refrigerant cylin-
ZERO CALIBRATION. der, Tara fresh oil or Tara used oil).
5. Remove the used oil bottle 2. Set the weight.
6. Enter the figure 00.00 and confirm with E. 3. Confirm with <Enter>.
?? The display shows
WEIGHT CALIBRATION. iiImportant note for older software versions:
7. Attach the calibrating weight The Tara values are NOT displayed. You always will
8. Enter the calibration weight value and confirm with see just value "0" in the menu where you can set the
E. Tara value.
""The menu containing the functions appears on the
display again. !!If you confirm with <Enter> in this menu, you set "0"
as new Tara value. If you don't want to change the
iiReturn with <Stop>. current value, you have to press the key "Stopp".
iiThe used oil scales can also be calibrated without a

calibration weight by filling the used oil bottle with
oil and entering the exact measured total weight of
the used oil bottle.

Calibration | ACS 511 | 33 en
13.5 Pressure sensor iiIf the simulator is not available, a simplified adjust-
13.5.1 Checking the adjustment ment can be performed. This process definitely guar-
1. Call up the start screen. antees that the ACS 511 will function perfectly.
2. Press <3> and <Flush> simultaneously and release.
?? The message ENTER CODE 0000 is displayed. 1. Turn on the ACS 511.
3. Enter 1515 and confirm with E . 2. Open the HP and LP valves on the display and con-
4. Select "INPUTS TEST" with o u and confirm with E . trol panel.
?? The absolute values of the scales and of the pres- 3. Start the vacuum function and maintain the vacuum
sure sensor is displayed. in the hoses for 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. After 5 minutes, stop the vacuum function and check
pressure sensor is subjected to the atmospheric on the pressure gages that there are no leaks.
pressure. 5. Call up the start screen.
6. Check that the pressure value read is between 0.900 6. Press <3> and <Flush> simultaneously and release.
and 1.100 bar (the typical value is 1.000 bar). ?? The message ENTER CODE 0000 is displayed.
7. Enter 1111 and confirm with E .
13.5.2 Adjusting the pressure sensor 8. Select "PRESSURE CALIBRATION" and confirm
with E .
iiThe pressure sensor is adjusted on the control PCB ?? ZERO CALIBRATION is displayed.
using the simulator, as the pressure sensor has been 9. Enter the value 0.000 on the keypad and confirm
officially calibrated in the factory. with E.
?? WEIGHT CALIBRATION is displayed.
iiPressure sensor 0 bar / 16 bar absolute 10. Detach the service hoses and set the pressure sen-
-1 bar / +15 bar relative. sor to atmospheric pressure.
11. Enter the value 1.000 on the keypad and confirm
1. Disconnect the pressure sensor from the control PCB. with E.
2. Connect the simulator to the control PCB. ?? The menu containing the functions appears on
3. Connect a multimeter to the simulator. the display again.
5. Press <3> and <Flush> simultaneously and release. iiReturn with <Stop>.
?? The message ENTER CODE 0000 is displayed.
6. Enter 1111 and confirm with E . 12. Perform the adjustment check described above
7. Select "PRES. CALIBRATION" with o u and con- (see section 12.4.1).
firm with E .
?? ZERO CALIBRATION is displayed.
8. Turn the potentiometer on the simulator until a volt-
age of 0 V is displayed.
with E.
?? WEIGHT CALIBRATION is displayed.
10. Turn the potentiometer on the simulator until a
voltage of 3.00 V is displayed.
with E.
?? The menu containing the functions appears on
the display again.
12. Remove the simulator and re-connect the pressure
sensor.

en 34 | ACS 511 | Component test
14. Component test 14.3 Control PCB input signal
14.1 LCD !!Follow the additional ACS 511 menu prompting.
!!Follow the additional ACS 511 menu prompting. 1. Call up the start screen.
1. Call up the start screen. ?? The message ENTER CODE 0000 is displayed.
2. Press <3> and <Flush> simultaneously and release. 3. Enter 1515 and confirm with E .
?? The message ENTER CODE 0000 is displayed. 4. Select "INPUTS TEST" with o u and confirm with
3. Enter 1515 and confirm with E . E .
4. Select "DISPLAY TEST" with o u and confirm with
E . iiReturn with <Stop>.
iiReturn with <Stop> ?? In order, the screen shows:

$$ Weight of the internal refrigerant cylinder
iiAll display pixels, followed by the LED displays, are $$ Weight of the fresh oil bottle
activated in sequence to ensure that they function $$ Weight o the used oil bottle
properly. $$ Pressure sensor value
14.2 Outputs iiThe values measured by the scales are absolute val-
ues, that means the real weight on the scales.
!!During this process, parts of the refrigerant circuit
are opened that may be pressurized. Therefore, 14.4 Printer
make sure beforehand that the pressure has been
drained from the refrigerant circuit (see section 8.1). iiThis function starts a short test print.
!!Follow the additional ACS 511 menu prompting. !!Heed the ACS 511 menu prompting.
1. Call up the start screen. 1. Call up start screen.

2. Press <3> and <Flush> simultaneously and release. 2. Press <3> and <Flush> simultaneously and release.
?? The message ENTER CODE 0000 is displayed. ?? The message ENTER CODE 0000 is displayed.
3. Enter 1515 and confirm with E . 3. Enter 1515 and confirm with E .
4. Select "OUTPUTS TEST" with o u and confirm 4. Select "PRINTER TEST " with o u and confirm
with E . with E .
iiReturn with <Stop> iiReturn with <Stop>.
iiAs 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
Solenoid valve EV10

Component test | ACS 511 | 35 en
14.5 Counter 14.7 Draining oil

Displays the following information:
$$ Prepared refrigerant iiThis function opens the solenoid valve EV7 and
$$ ACS 511 operating hours, drains the pressure in the compressor. This enables
$$ Vacuum pump operating hours the solenoid valve EV7 to be serviced.
iiThis function displays the total number of operations !!Follow the additional ACS 511 menu prompting.
performed with the ACS 511 since initial commis-
sioning. 1. Call up the start screen.
!!Follow the additional ACS 511 menu prompting. ?? The message ENTER CODE 0000 is displayed.
1. Call up start screen. 4. Select "OIL DRAIN PROGRESS " with o u and
2. Press <3> and <Flush> simultaneously and release. confirm with E .
3. Enter 1515 and confirm with E . iiReturn with <Stop>.
4. Select "COUNTERS " with o u and confirm with E .
?? EV7 appears on the display.
iiReturn with <Stop>. $$ Select <MENU> to open EV7.
$$ Leave EV7 open until there is no more pressure in
the compressor.
14.6 Service printout $$ Select <STOP> to close EV7 and perform the
maintenance tasks on the solenoid valve.
iiThis function allows you to print out a service report
containing important information about the A/C
services carried out.

4. Select "SERVICE PRINTING " with o u and con-
firm with E .
?? The following data appears in the service print-

out:
$$ Total quantity of refrigerant recovered
$$ Vacuum pump operating hours
$$ Scale adjustment data for fresh oil and used oil
$$ Fresh oil scales adjustment date
$$ Used oil scales adjustment date

en 36 | ACS 511 | Changing basic settings
15. Changing basic settings 1. Call up the start screen.

iiThe set values guarantee that the ACS 511 will ?? The message ENTER CODE 0000 is displayed.
function perfectly. These parameters may only be 3. Enter 5599 and confirm with E .
changed by an A/C service unit engineer and after 4. Select the relevant parameter with o u and confirm
approval from the manufacturer. with E .
!!Follow the additional ACS 511 menu prompting. iiReturn with <Stop>.
Param- Actions Default Param- Actions Default

eter eter
P1 System pressure empty. 1500 T20 Vacuum test time for flushing operation. 120
Absolute pressure value above which re- Time in seconds for the vacuum test dura-
covery begins. tion in the flushing function.
P2 Pressure at end of recovery. 600 T21 EV7 oil outlet open duration. 180
Absolute pressure value above which re- Time in seconds for which the solenoid
covery ends. valve EV7 remains open during the oil out-
P3 Vacuum test pressure. 300 let function.
Absolute pressure value after which the W1 Combo filter replacement threshold. 10
vacuum test turns out to be negative. Value in kilograms before a prompt to re-
T1 Vacuum pump oil change threshold. 10 place the combo filter appears on the dis-
Number of hours before a prompt to play.
change the vacuum pump oil appears on W6 Max. capacity of small bottle. 10000
the display. Value in grams that represents the maxi-
T2 Time for automatic emptying. 120 mum quantity for filling the small internal
Value in seconds for duration of automat- refrigerant cylinder.
ic emptying. W8 Max. capacity of large bottle. 20000
T3 Maximum time for recovery. 30 Value in grams that represents the maxi-
If this time is exceeded, the function is mum quantity for filling the large internal
aborted and the message "LONG EXTRAC- refrigerant cylinder.
TION TIME" appears on the display. OUTOIL2 Maximum capacity of used oil bottle. 250
T4 Weight variation monitoring threshold 60 If this value is exceeded, the message
Time in seconds in which the weight (re- "USED OIL BOTTLE FULL, EMPTY CON-
covered quantity) must change during re- TAINER" appears.
covery, otherwise the operation is abort- OUTOIL3 Not used
ed. HOSE Minimum time for cleaning the service 60
T5 Oil outlet time. Time in minutes for the oil 5 CLEAN- hoses. This is the minimum value in sec-
drainage duration. ING TIME onds for emptying the service hoses af-
T7 Specified time for vacuum. The mean time 20 ter filling.
recommended by car manufacturers is 20 CON- Activates and deactivates the "Save data 0 (off)
minutes. TROL RE- via ACUSB PC interface" function.
T8 Not used. PORT
T9 Vacuum test duration. 300 COMPEN- Activates and deactivates the "Compen- 0 (off)
Time for checking any pressure increase SATION sation at 0 in filling phase" function (i.e.
after the vacuum function has been exe- AT 0 compensation is deactivated).
cuted. BYPASS Activates and deactivates the "Bypass" 0 (off)
T10 Recycling plus vacuum time. 10 function. If this function is activated, the
Time in minutes for the duration of the re- MENU key skips the waiting times for the
cycling plus vacuum function. main ACS 511 functions.
T13 Maximum time for the filling process. 20 RENAULT Mode required by Renault. 0 (off)
If this time is exceeded, the function is CONFIG The times between two recoveries are ex-
aborted and the message "FILLING IN- tended. This mode can be activated or de-
COMPLETE" appears on the display. activated as required
T14 EV9 UV contrast medium open duration. 5 BACKUP See section 14.2.
Time in seconds for which the solenoid
valve EV9 is open. Corresponds to the
time for which UV contrast medium is
added.
T15 Maximum time for the oil filling process. 10
If this time is exceeded, the function is
aborted and the message "HIGH OIL FILL-
ING TIME" appears on the display.
T16 Maximum time for the flushing process. 15
If this time is exceeded, the function is
ended and the process continues.

Software | ACS 511 | 37 en
16. Software !!Do not use the PS2 stick with the new software ver-
sion, as the stick is cleared before the data backup.
16.1 Vehicle database
6. Insert PS2 stick.
iiThe vehicle database can be updated annually using 7. Confirm that any data on the stick will be deleted.
a PS2 stick. Further information can be obtained 8. After the backup, remove the stick.
from customer service. ""The data is saved.
!!Do not switch off ACS 511 during update process. 16.3 Software update
!!Follow the additional ACS 511 menu prompting. iiThe software is updated using a PS2 stick. Before
updating, perform a data backup (see section 13.2)
1. Call up the start screen. so that the calibration data and settings for the
2. Press <3> and <Flush> simultaneously and release. ACS 511 will not be lost.
3. Enter 2222 and confirm with E . 1. Turn off the ACS 511.
4. Select "DATABASE UPDATE" with o u and con- 2. Insert the "System Software" PS2 stick.
firm with E . 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. 6. Remove the PS2 stick.
6. Insert PS2 stick. 7. Turn on the ACS 511.
7. Activate or deactivate with o u and confirm with E.
?? The update is performed. 16.4 Loading a data backup
""Data base is updated.
iiThe calibration data previously saved (section 14.2)
iiReturn with <Stop>. can be reinstalled after the software update.
16.2 Data backup 1. Turn off the ACS 511.

2. Insert the "Data Backup" PS2 stick.
iiThis function enables you to save ACS 511 configura- 3. Press and hold the <MENU> key.
tion data before a software update. A data backup 4. Turn on the ACS 511 and release the <MENU> key.
avoids the need to recalibrate the ACS 511 after a 5. After recovery of the data, remove the PS2 stick and
software update. attach the plastic cover.
6. Check the calibration data.
!!Do not turn off the ACS 511 while saving.

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.

en 38 | ACS 511 | Circuit diagram
17. Circuit diagram

17.1 Control PCB
Fig. 6: Control PCB
Fig. 7: Control PCB

Circuit diagram | ACS 511 | 39 en
17.2 Computer printed circuit board
1
CPU
TANK
2
8
PRN
3
RS232-B
IN OIL
7 4
PROGRAM
OUT OIL PRESSURE
6
5
RS-232
Fig. 8: Computer printed circuit board

1 Internal refrigerant scales connection
2 Pressure sensor connection
3 Fresh oil scales connection
4 Used oil scales connection
5 Pressure sensor connection
6 Internal printer connection
7 Programming connection
8 Serial connection
9 Control PCB connection (supply PCB)

en 40 | ACS 511 | Circuit diagram
17.3 Circuit diagram ACS 511
Fig. 9: Circuit diagram ACS 511

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

1 689 975 252 | 2016-08-24

En Repair Instruction A/C Service Unit

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ACS 511

2. Important information 4 11. TROUBLESHOOTING AND ANALYSIS 25

8. Service phases 11 13. Calibration 31

1 689 975 252 | 2016-08-24 Robert Bosch GmbH

14. Component test 34 1. Symbols used

Symbol Designation Explanation

! Attention Warns about possible property damage.

1.2 On the product

!!Observe all warning notices on products and ensure

¶¶ Wear safety goggles.

¶¶ Wear protective gloves.

¶¶ Protect against dampness and moisture.

Robert Bosch GmbH 1 689 975 252 | 2016-08-24

2. Important information 3. Test equipment and auxil-

1 689 975 252 | 2016-08-24 Robert Bosch GmbH

4. Safety regulations RR R134a is not to be used in areas in which there is a

4.2 Handling UV dye

Robert Bosch GmbH 1 689 975 252 | 2016-08-24

4.4 Notes on operation 4.5 Maintenance work

the brake. Rated voltage 230 VAC ± 10 %

1 689 975 252 | 2016-08-24 Robert Bosch GmbH

Fig. 1: Front view Fig. 2: Rear view

Robert Bosch GmbH 1 689 975 252 | 2016-08-24

6 Refrigerant is evacuated from the

RR Control up RR Cursor moves up.

1 689 975 252 | 2016-08-24 Robert Bosch GmbH

6. Program structure 6.6 Manual mode

LANGUAGE Input Menu

1. + <3> DATE/TIME SELECT PORTS

6.4 Vehicle and customer data

Robert Bosch GmbH 1 689 975 252 | 2016-08-24

Name Description Name Description Name Description

1 689 975 252 | 2016-08-24 Robert Bosch GmbH

iiOpening the HP and LP valves on the ACS 511

iiThe pressure sensor P1 checks the pressure of the

3. starts extraction of the refrigerant.

RR The refrigerant flows through the solenoid valves

Robert Bosch GmbH 1 689 975 252 | 2016-08-24

Name Description Name Description Name Description

1 689 975 252 | 2016-08-24 Robert Bosch GmbH

Name Description Name Description Name Description

Robert Bosch GmbH 1 689 975 252 | 2016-08-24

1. The ACS 511 is connected to the vehicle with the

1 689 975 252 | 2016-08-24 Robert Bosch GmbH

Name Description Name Description Name Description

Robert Bosch GmbH 1 689 975 252 | 2016-08-24

iiThe HP and LP valves are open and all solenoid

Name Description Name Description Name Description

1 689 975 252 | 2016-08-24 Robert Bosch GmbH

8.5 Refrigerant preparation iiInternal preparation of the refrigerant is the same

Name Description Name Description Name Description

Robert Bosch GmbH 1 689 975 252 | 2016-08-24

Name Description Name Description Name Description

1 689 975 252 | 2016-08-24 Robert Bosch GmbH

Name Description Name Description Name Description

Robert Bosch GmbH 1 689 975 252 | 2016-08-24

8.8 Filling refrigerant iiOpen EV3 and EV6.

Name Description Name Description Name Description

1 689 975 252 | 2016-08-24 Robert Bosch GmbH

Name Description Name Description Name Description

Robert Bosch GmbH 1 689 975 252 | 2016-08-24

Name Description Name Description Name Description