Bosch ACS 511 Setup guide

ACS 511
en Repair instruction
A/C Service Unit

1 689 975 252 2019-05-15| Robert Bosch GmbH
2 | ACS 511 |en
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 Handling UV dye 5
4.3 Working on the vehicle 5
4.4 Notes on operation 6
4.5 Maintenance work 6
4.6 Safety devices 6
4.7 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 and recycling
(simultaneous) 14
8.3.1 Vacuum phase 14
8.3.2 Recycle 14
8.4 Leak test 16
8.5 Refrigerant preparation 17
8.6 Fresh oil filling 18
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
9. Troubleshooting 23
9.1 Service messages 23
9.2 Fault messages 23
10. Emptying the ACS 511 24
10.1 Automatic emptying 24
10.2 Extraction of internal refrigerant circuit with sec-
ond A/C service unit 24
11. TROUBLESHOOTING AND ANALYSIS 25
11.1 Faults during recovery 25
11.1.1 Compressor starts 25
11.1.2 Compressor does not start 25
11.1.3 Fault messages that can occur during
recovery 26
11.1.4 Other fault messages 26
11.2 Faults during the vacuum phase 26
11.2.1 The vacuum pump starts 26
11.2.2 The vacuum pump does not start 26
11.2.3 Fault message that can occur during the
vacuum phase 27
11.3 Faults during refrigerant preparation 27
11.4 Non-condensing gases are not drained 27
11.5 Faults during filling with refrigerant 27
11.5.1 Vehicle air conditioning system cannot be
filled 27
11.5.2 Other fault messages 27
12. Component test and maintenance 28
12.1 Vacuum pump 28
12.2 Pressure sensor P1 28
12.3 Pressure switch P2 28
12.4 Expansion valve 28
12.5 Combo filter 29
12.5.1 Replacement of combo filter 29
12.5.2 Reset filter 29
12.6 Vacuum pump 30
12.6.1 Changing vacuum pump oil 30
12.6.2 Reset of oil change interval 30
13. Calibration 31
13.1 Internal refrigerant cylinder scales 31
13.2 Fresh oil bottle scales 31
13.4 Tara values 32
13.3 Used oil bottle scales 32
13.5 Pressure sensor 33
13.5.1 Checking the adjustment 33
13.5.2 Adjusting the pressure sensor 33

1 689 975 252 2019-05-15|Robert Bosch GmbH
Symbols used | ACS 511 | 3 en
1. Symbols used
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 con-
sequences of the hazard as well as preventive action.
Warning notices have the following structure:
Warning
symbol KEY WORD – Nature and source of hazard!
Consequences of hazard in the event of fail-
ure to observe action and information given.
¶Hazard prevention action and information.
The key word indicates the likelihood of occurrence and
the severity of the hazard in the event of non-obser-
vance:
Key word Probability of
occurrence
Severity of danger if in-
structions not observed
DANGER Immediate impend-
ing danger
Death or severe injury
WARN-
ING
Possible impending
danger
Death or severe injury
CAUTION Possible dangerous
situation
Minor injury
1.1.2 Symbols in this documentation
Symbol Designation Explanation
!Attention Warns about possible property damage.
iInformation Practical hints and other
useful information.
1.
2.
Multi-step
operation
Instruction consisting of several steps.
eOne-step
operation
Instruction consisting of one step.
 Intermediate
result
An instruction produces a visible inter-
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.
14. Component test 34
14.1 LCD 34
14.2 Outputs 34
14.3 Control PCB input signal 34
14.4 Printer 34
14.5 Counter 35
14.6 Service printout 35
14.7 Draining oil 35
15. Changing basic settings 36
16. Software 37
16.1 Vehicle database 37
16.2 Data backup 37
16.3 Software update 37
16.4 Loading a data backup 37
17. Circuit diagram 38
17.1 Control PCB 38
17.2 Computer printed circuit board 39

1 689 975 252 2019-05-15| Robert Bosch GmbH
4 | ACS 511 | Important informationen
2. Important information
Installation and/or repairs must only be performed by
trained and instructed Bosch customer service rep-
resentatives or companies authorized by Bosch If the
units are opened or modified by unauthorized persons,
any warranty claims become void.
Electrical systems and devices must only be put into
operation when in proper operating condition (details
can be found in the EDIS-Info 200108_084). This re-
quirement is met if following modification or repair (ini-
tial testing) it is ensured that the requirements of the
electrical engineering directives were adhered to. To
check this, tests should be performed, the nature and
extent of which are based on the measures specified in
the electrical engineering directives (e.g. in Germany
DGUV Vorschrift 3). The type and extent of the tests are
described in VDE 0701/0702 Part 1 within Germany.
The relevant national directives must be complied with.
3. Test equipment and auxil-
iary materials
RGeneral tools for electricians and A/C mechanics
RDigital multimeter (e.g. MMD 003)
RLoctite 542 (for thread seal) and 222 (for thread
lock)
RCleaning agent (e.g. brake cleaner)
RCalibrating weights 250 - 500 g for oil bottle scales
RCalibrating weight 10 - 20 kg for internal refrigerant
scales
RLeak detector (1 689 100 057)
RSimulator (optional)

1 689 975 252 2019-05-15|Robert Bosch GmbH
Safety regulations | ACS 511 | 5 en
4. Safety regulations
!Always carefully read and observe all the safety regu-
lations 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 (ap-
prox. -30 °C) can lead to frostbites. Should
it nevertheless come into contact with the
skin, remove any moistened clothing imme-
diately and rinse the affected skin with copi-
ous amounts of water.
RR134a is colorless, has a weak intrinsic odor and is
heavier than air. It displaces oxygen and may flow
into repair pits. Should refrigerant escape (malfunc-
tion), 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 respi-
ratory system. If liquid refrigerant comes
into contact with the eyes, rinse them thor-
oughly with water for 15 minutes. Then ob-
tain medical help even if no pain is felt.
RBefore connecting the ACS 511 to a vehicle air con-
ditioning system or an external refrigerant cylinder,
make sure the quick-release couplings are not leak-
ing.
ROnly ever use external refrigerant cylinders provided
with safety valves and certified in line with the ap-
plicable standards.
RBefore switching off the ACS 511, make sure all fill-
ing and drainage operations have been completed.
This prevents refrigerant escaping into the environ-
ment.
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.
RRefrigerant extracted from a vehicle air conditioning
system may be contaminated with moisture, lubri-
cant, dirt and traces of other gases.
RR134a is not to be used in areas in which there is a
danger of explosion. Fire, naked flames and smok-
ing are prohibited. Welding and soldering are not
permitted.
RHigh temperatures and UV radiation may chemically
separate the R134a. The resultant products cause
coughing and nausea.
RR134a is not to be mixed with other refrigerants.
The mixing of refrigerants can damage the vehicle air
conditioning system.
4.2 Handling UV dye
Never inhale UV dye. The vapors can irritate the
eyes, nose and respiratory system. If UV dye
comes into contact with the eyes, rinse them
thoroughly with water for 15 minutes. Then
obtain medical help even if no pain is felt.
RAvoid all skin contact with the UV dye. Should it nev-
ertheless come into contact with the skin, remove
any moistened clothing immediately and rinse the
affected skin with copious amounts of water.
RNever swallow UV dye. If swallowed inadvertently,
never attempt to induce vomiting. Drink copious
amounts of water and obtain medical help.
4.3 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 possi-
ble transmission of current through the body.
RDe-energization is only to be performed by a quali-
fied electrician, a qualified electrician for specific
tasks (hybrid), or a power systems engineer.
RWork 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".
REven after deactivating the high-voltage vehicle
electrical system, the high-voltage battery may still
be live.
RThe operating condition cannot be established from
any running noise, as the electric machine is silent
when stationary.
RIn gear positions "P" and "N" the engine or electric
motor may start spontaneously depending on the
charge of the high-voltage battery.
RNever open or damage high-voltage batteries.