Bosch ACS 553 User manual
en
Repair instruction
A/C Service Unit
ACS 553 - ACS 553-P - ACS 563 - ACS 563-P
ACS 553, ACS 563 Service Manual
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© Robert Bosch GmbH
Robert Bosch GmbH
Franz-Oechsle-Straße 4
1119D-73201 Plochingen
SERVICE: [email protected]
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Carefully read all instructions.
Do not use in open air in case of rain or high humidity.
Wear gloves.
Wear protection goggles.
Alternating voltage.
Grounding protection.
Electrical shock hazard.
Safety signal words designate the degree, or level, of hazard seriousness.
: Indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury.
: Indicates a potentially hazardous situation which, if not avoided, could result
in death or serious injury.
: Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury.
: Used without the safety alert symbol indicates a potentially hazardous situation which,
if not avoided, may result in property damage.
These safety messages cover situations Bosch is aware of. Bosch cannot know, evaluate, or
advise you as to all possible hazards. You must verify that conditions and procedures do not
jeopardize your personal safety.
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Beforeoperating
the machine, read and follow all instructions and warnings in this manual. The operator must
be familiar with air conditioning and refrigeration systems, refrigerants, and the dangers of
pressurized components. If the operator cannot read this manual, all operating instructions
and safety precautions must be read and discussed in the operator’s native language.
Using the machine in a manner for
which it was not designed will compromise the machine and nullify the protections provided.
Contact with
refrigerant may cause personal injury, including blindness and frozen skin. Wear protective
Ensure the phase has been completed before disconnecting the machine to prevent the
release of refrigeration to the atmosphere.
Refrigerant
mechanical ventilation that provides at least one air change per hour. If accidental system
discharge occurs, ventilate the work area before resuming service.
Such a precaution
is necessary to prevent the possible presence of refrigerant in the working environment.
The refrigerant R1234yf (for ACS 563 only) is heavier than air and tends to concentrate
in the pits of the workshop.
do not use the machine in the vicinity of spilled or open
with a minimum size of 14 AWG.
hot surfaces.
, do not use the machine in environments containing
D
or areas. Protect the machine from conditions that may cause electrical failure or other
hazards relating to ambient interaction.
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machine.
Disconnect the electrical supply before a long period of inactivity or before internal
maintenance is performed.
(The machine is equipped with
special connectors to recover, recycle, and recharge only R1234yf ( ACS 563) or R134a
(ACS 553) refrigerant. Do not attempt to adapt the machine for another refrigerant. Do not
cause severe damage to the machine and the vehicle air conditioning system.
Do not use refrigerants other than those indicated on the technical data plate. It is also
recommended to buy it from specialized companies that guarantee its good quality.
Protect the machine from conditions that may cause electrical failure or other hazards
relating to ambient interaction.
Position the machine far from
of this machine under normal environmental conditions (10°C to 50°C) keeps pressures
indicated on the technical data plate.
.
and do not subject them to vibration.
Further information regarding health and safety may be obtained from the refrigerant
manufacturer.
)To minimize the risk of ignition, the unit software guided leak check
is periodically performed otherwise the unit will lock. For same purpose, also hardware features
such as ventilation fan monitoring system, suitably located vents on cart bottom (R1234yf is
heavier than air) and sealed power switching circuits are present.
.
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.
The machine is equipped with the following protective devices:
• Over pressure valves.
•
.
.
.
country regulations and norms. Parts in the scope of PED are:
• Tank.
• Pressure relieve valve.
• High pressure switch.
• Recovery group.
• Piping.
inserted. On slightly irregular surfaces, the unit can be moved by keeping it slightly inclined and
.
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Repair of the ACS 553, ACS 563 may only be performed by service technicians, trained in
handling of refrigerants, personal protective equipment, refrigerant leakage prevention, handling
of charging, leak detection and proper disposal.
Service technicians must be trained and certified by Robert Bosch GmbH or its regional
authorized by Robert Bosch GmbH in servicing the ACS 553, ACS 563.
For specific work, the service technician needs the following additional qualifications
• Electrotechnical knowledge for working on electrotechnical systems and equipment
as per EN 50110-1 and EN 50110-2 (see accident prevention regulation for electrical systems
•
All warranty claims (personal injury, faulty equipment) are rendered null and void if the ACS 553,
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Introduction
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Introduction
refrigerant. Follow recommended service procedures for the containment of refrigerant.
12 3
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1. Gauge low pressure (LP)
2. Display and control panel
3. Gauge high pressure (HP)
4.
5. Main power supply switch
6. Fuse holder
7. Power supply socket
Fresh oil bottle (PAG or POE)
9. Oil drain bottle
10.Printer (optional, standard on P variants)
11. Service hose port (high pressure*)
12.Service hose port (low pressure*)
13.Contaminant recovery outlet port
(for R1234yf only)
14.Flush port (high pressure*)
15.Flush port (low pressure*)
16.
17.Front wheels with locking brake
Rear wheels
19.Vacuum pump
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Introduction
moves selection of a
menu item to the previous item.
moves selection of
a menu item to the following item.
screen.
scrolls to previous
screen.
(function keys)
to select the functions shown on
display (bottom icons).
Thecan be used to
enter letters, numbers and special
0...9
A...Z
supplies information
regarding charge capacity by vehicle
model.
activates a menu that
helps the user set up an automatic
sequence.
activates the sequence
to recover refrigerant from the vehicle
activates the sequence
that pulls a deep vacuum on the
and moisture.
activates the sequence
with a programmed amount of
refrigerant.
displays information related to
the current display.
accesses additional functions
and parameters.
or step.
to return to the previous
screen or step.
to enable or disable the
selected function.
to confirm, proceed or save
settings.
to cancel the operation and
return to the previous function or the
Main menu.
to move menu selection upward.
to move menu selection
downward.
to perform a print (only for
variants with printer).
to erase the character
to the left of the cursor.
to pause a process.
to resume a paused process.
to repeat the last step.
to delete a selected entry
from the memory of the machine.
indicates that the WiFi
connection is enabled.
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Introduction
The machine launches into the initial Setup
It is needed to complete all the setup
Carry out the following setup:
1. Language selection.
2. License agreement review.
4. Date and Time adjustment.
5. Edit Print Header.
6. Service Vacuum.
7. Oil inject viscosity selection.
At the end of the initial setup procedure it is
suggested to:
•
only).
1. Call up the Main Menu.
2. Select icon.
3. Select icon.
• Select to access the following
functions.
a vehicle with a refrigerant already present.
Flushes residual oil from the machine to prepare
Provides a method of removing oil and impurity
Use this function to transfer refrigerant from a
be adjusted up or down to suit the user’s needs.
Refer to “Tank Fill” in the Maintenance section.
The vehicle air conditioning
system being serviced.
Moisture and other incondensables
vacuum pump.
The tank
designed specifically for this machine has
the ACS 553 has a disposable capacity of
Model No. ACS 553 or ACS 563.
Different oil types in the vehicle
air-conditioning system depending on the
vehicle manufacturer.
Refrigerant is recovered
ISV.
R134a (ACS 553) or R1234yf
(ACS 563).
A disposable tank
included.
indicates that the
Bluetooth connection is enabled.
to set which side to charge
thru (high pressure, low pressure or
both sides).
to set the unit of measurement
(ml or oz).
to set the unit of measurement
(kg, oz or lb).
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Introduction
Function to memorize the refrigerant amount
recovered and charged for every vehicle. The
: to show data of recovered and
charged refrigerant.
with recovered and charged refrigerant
USB stick, recommended size 2 GB and
FAT format (support is not part of scope
delivery). Data are transferred as
: to erase all data stored
on the machine.
: to print all data stored
on the machine.
: to disable the
Refrigerant tracking function.
To flush the oil injection port in case of oil
change. Plug the bottle to be used (PAG or
POE) into the oil injection port, before starting
the function.
• Select icon to return to the Setup
Menu.
• Select to access the following
functions.
Select a language for screen prompts. English
is the default language.
Program the machine to display metric or
imperial values. The default display is in a
metric system.
Program the machine for current date and time.
Programs information that will appear on the
printout each time a print function is used.
Failure to register and activate the machine
within 30 days of initial startup will cause the
machine to lock out and not function. Select
this Settings Menu item and follow the prompts
To enable or disable the purity test of the
USB port of the machine. The display shows
three selection options:
:
Displays the steps required to perform the
purity test.
:
Does not display the steps required to
perform the purity test.
: Ask a
whether or not to perform the purity test.
Program the machine to change duration of the
vacuum leak test time.
Program the machine to turn the buzzer on or
via WiFi (with Bosch WiFi dongle - optional -).
-
ware updates are available.
: To upgrade the firmware
through a USB stick.
through a WiFi network. If the unit is con-
nected to WiFi network and the WiFi net-
work is connected to Internet, it will auto-
matically start searching for new updates.
: to check or install
the firmware update of the Refrigerant
: to check or
install the firmware update of the WiFi
dongle, if available.
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Introduction
: To search for
available WiFi networks.
: To display some WiFi
connection data used.
: to perform a WiFi
network connection test used by the
machine.
: To disable
the WiFi network connection stored on the
machine.
: to perform manual scan
and selection of WiFi network.
To enable or disable the asanetwork function.
For further information contact Customer
Service.
To enable or disable the CoRe function.
For more information see Connected Repair
[CoRe] chapter on the user manual.
• Select icon to return to the Setup
Menu.
• Select to access the following
functions.
from the refrigerant. To meet requirements, it is
Model
R134a
(alert 56 kg)
Model
R1234yf
This menu item displays the filter capacity
remaining until the machine locks down and no
longer functions. Refer to “Filter Maintenance”
in the Maintenance section.
Displays the amount of time remaining until
is replaced. Refer to the “Vacuum Pump
Maintenance” in the Maintenance section.
Displays internal storage vessel (ISV) pressure
and temperature. It is used to eliminate
incondensables gas and helps to limit the
pressure in the ISV.
Use to verify internal scale calibration. Refer to
“Calibration Check” in the Maintenance section
of this manual.
To activate or deactivate the pressure values
display of the machine.
Displays the revision level of the software in
the unit.
Performs double test (in vacuum and pressure)
to detect any leakage on the machine.
For service center use only.
For production use only.
“Calibrate Air Flow” in the Diagnostics and
Testing section.
• Select icon to return to the Setup
Menu.
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Introduction
Do not use abrasive cleaning agents, solvents
(petrol, diesel, etc.) and coarse workshop cloths
to clean the machine. Clean only using a soft
cloth and neutral cleaning agents.
In cases of refrigerant leaks, such
as during installation, maintenance or repair
of machine, or even during normal use after
machine rest, there will be no refund by the
manufacturer.
.
ACS 553 - ACS 563 is equipped with 2 protection
fuses. If the protection fuses are blown, the
1
• Replace the fuses (1) (6.3A F) if blown
to restore the power supply of ACS 553 -
ACS 563.
This menu (available on Function menu) is
used to transfer refrigerant from a source tank
to the ISV.
1. Call up the Main Menu.
2. Select icon.
3. Select icon.
4. Select from the Functions
Menu. The machine displays:
RECOVER CAPACITY
CHARGE CAPACITY
5.
enough liquid refrigerant is available for
charging and select icon. Unit is set
shown on display anymore). If the source
6. Connect the low pressure service hose (blue)
to the liquid connector on a full source tank.
7. Position the source tank in such a way
that liquid refrigerant is supplied to the
connection. Open the source tank valve.
Select
9.
identifier is enabled) checks the
refrigerant in the source tank to verify
it is R1234yf and not contaminated.
The machine displays the following screens:
INITIALIZING REFRIGERANT IDENTIFIER
ANALYZING REFRIGERANT SAMPLE
REFRIGERANT PURITY PASSED
10.The machine begins filling the internal
storage vessel (ISV) and automatically
stops when the preset tank fill level is
reached. To stop the tank fill before the
preset level is reached, select icon.
11. Close the liquid valve and remove the hose
from the source tank.
12. Select icon to return to the Function Menu.
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Introduction
and to remove water from refrigerant. To meet
The unit gives a warning when (SEE TABLE) of
down when the
(
been reached and will no longer function.
1. Call up the Main Menu.
2. Select icon.
3. Select icon.
4. Select from the
Maintenance Menu or when the machine
prompts. The machine displays:
REMAINING FILTER CAPACITY: XXX.XYY
REPLACE FILTER NOW?
• The machine displays amount of filter
capacity remaining until the machine
locks down. This message may occur at
maintenance action.
5. Select
icon to resume using the machine.
1. If icon
ENTER NEW FILTER SERIAL NUMBER
If SERIAL NUMBER WRONG is
displayed, the serial number has been incorrectly
machine.
2. Use the keypad to enter the serial number
icon to continue.
•
displays:
TURN POWER OFF
AND REPLACE FILTER
3.
4. Remove the old filter (1) by turning it
counterclockwise. Refer to Figure 1-4.
1
5.
are lubricated and correctly located in the
grooves as shown in Figure 1-5.
6. Install the new filter by threading it
clockwise into place. Verify the filter is
positioned correctly. Tighten the filter to
20 Nm ± 1.
7. Switch on the machine.
Machine starts with vacuum pump oil
change (Refer to the “Vacuum Pump
Maintenance” in this section).
9.
the machine according to the laws in your
jurisdiction.
.
Model
R134a
(alert 56 kg)
Model
R1234yf
O-rings
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Introduction
Vacuum pump oil must be changed with
or more often as necessary.
1. Call up the Main Menu.
2. Select icon.
3. Select icon.
4. Select from the
Maintenance Menu or when prompted.
The display shows how long the vacuum
pump has operated since the last oil change.
REMAINING OIL LIFE XXX:XX (hhh:mm)
CHANGE OIL NOW?
5. Select icon to change vacuum pump oil.
6. If the the machine displays:
WARMING OIL FOR DRAIN
• allow the vacuum pump to run for two
minutes to warm up the oil.
7. If the oil is already warm, the display shows:
DRAIN USED OIL FROM PUMP AND REPLACE
WITH 250 ML OF NEW OIL REMOVE CAP TO
SPEED DRAINING OF OIL
there is no pressure in the machine. Then
carefully remove the cover. See Figure 1-6.
9. Remove the oil drain fitting cap (3) and
drain the oil into a suitable container for
disposal. Reinstall the oil drain cap (3) and
close tightly.
10. Slowly add vacuum pump oil to the pump
the center of the sight glass (1)
.
11.
tightly.
12.Select icon to continue.
13.The display show a message that indicate
to the user to check that the oil level is at
the center of the sight glass pump.
In case it is necessary to add more oil,
14.Select icon to return to the Maintenance
Menu.
.
Review the laws and regulations in
your jurisdiction to determine correct disposal
procedures for pump oil. It is the responsibility
of the user to determine if a material is a
hazardous waste at the time of disposal.
The user must ensure compliance with all
applicable laws and regulations.
1
3
2
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Introduction
in Setting menu) appearing in the header on
each printout:
1. Call up the Main Menu.
2. Select icon.
3. Select icon.
4. Select in the Settings
5.
multi-tap interface on the numeric keypad:
icon acts as a backspace
key.
or arrow moves the cursor to the
right or to the left.
(0) key also acts as a spacebar.
and arrows navigate between
the rows.
6. Select icon to save the changes and
return to the Settings Menu.
7. Select
Settings Menu.
To install a new paper roll in the printer:
1. Remove the cover on the printer by pulling
out on the tab (2) as shown in Figure 1-7.
2. Remove the paper core.
3. Install the new roll of paper with the end of
the paper at the top of the roll.
4. Assemble the cover onto the printer with the
leading edge of the paper over the roller (1).
1
2
This function is used to ensure the machine’s
internal scale is always calibrated. To perform
this check make use of Bosch calibration kit
(optional) including sample weight and magnet.
First time magnet must be installed.
1. Verify the magnet on the bottom of the
2. Call up the Main Menu.
3. Select icon.
4. Select icon.
5. Select from the Mainte-
nance Menu. The machine displays:
PLACE CALIBRATION WEIGHT ON MAGNET
LOCATED ON THE BOTTOM OF MACHINE
6. Attach the calibration weight to the magnet
(1) on the bottom of the machine.
7. Select icon to continue.
.
The machine displays:
REMOVE CALIBRATION WEIGHT
FROM MAGNET LOCATED
ON THE BOTTOM OF MACHINE
Remove calibration weight from magnet
located on the bottom of machine.
9. Select icon to continue.
• If the display shows
the scale is calibration. Select icon to
return to the Maintenance Menu.
• If the display shows the
scale is out of calibration. Select
icon to retry. If calibration continues to fail,
contact an authorized service center for
assistance.
1
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Introduction
This function is available on Maintenance menu.
To ensure a safe, environmentally friendly,
and economic operation, the unit performs a
software-controlled self-test in regular intervals
every 10 days (for R1234yf only).
1. Follow the on-screen prompts to connect
the hose service couplers to the storage
connectors on the side of the machine.
Open the hose couplers by turning the
collars clockwise.
2. Select icon to start the test.
3. The machine performs a self-recovery and
displays:
RECOVER IN PROGRESS
4. The machine performs a 30-second vacuum
test and displays:
VACUUM CHECK IN PROGRESS
• If the vacuum test fails, the machine will
prompt to check for leaks.
5. Once the machine passes the vacuum test,
a controlled pressure is applied to its internal
components. The machine displays:
PRESSURE CHECK IN PROGRESS
6. Pressure is held for five minutes and
monitored for decay. There is not a default
pressure value. The machine monitors the
pressure reached during the pressurization.
Minutes and seconds count down on the
display.
• If an acceptable pressure decay is detected,
the machine recovers refrigerant until
-0,44 bar and returns to the Maintenance
Menu, ready for normal operation.
• If an unacceptable pressure decay is
detected, the machine will prompt to
check for leaks. Take the machine to an
authorized service center for repair.
Leak Check may also be selected at
any time from the Maintenance Menu. If you
decline to run the Leak Check when prompted,
the machine will continue to prompt for the test
at each power-up until the test is completed
(for R1234yf only).
For the printer installation follow instructions
hereby:
1.
2. Remove the printer protective cover.
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3
4
5
3
33
62
1
3. Remove the four screws (3) from the control
panel (2).
4. Tilt the control panel (2) upwards the front
of the unit.
5. Connect the RS232 cable (5) and the power
supply cable (6) to the suitable connectors
on the printer (1).
6.
7. Connect the RS232 cable (5) to the
connector of the control board.
Connect the power supply cable (6) to the
connector of the control board.
9. Tilt the control panel (2) down and secure
with four screws (3).
10.Connect again the machine to the power
supply system and switch it on.
11. The printer is ready to be used.
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Introduction
For the magnet installation, refer to Figure 1-10.
1. Plug the magnet (1) within the housing
underneath the machine base.
“Calibration check” in this section.
1
For the conversion kit installation follow
instructions hereby:
1. Call up the Main Menu.
2. Select icon.
3. Select icon.
4. Select " and
enter password then select icon.
5. Select and select
icon to start the function.
second recovery machine with same refrigerant
and suitable free capacity.
6.
display. Turn on the recovery unit and select
icon.
7. Start the recovery function from the recovery
unit.
In case of recovery machine without
deep-recovery capabilities, perform vacuum for
Disconnect the recovery machine and
connect hoses as indicated at display.
9. Select icon to start the vacuum function.
step “Convert unit refrigerant” only if previous
“AC unit emptying” has been completed
successfully.
This manual suits for next models
3
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