Bosch ACS 810 Repair Instructions
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Bosch ACS 810 Repair Instructions

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Summary of Contents for Bosch ACS 810

  • Page 1 ACS 810 A/C service unit en Repair instructions A/C service unit...

  • Page 2: Table Of Contents

    | 2 | ACS 810 | en – Contents Troubleshooting Service messages Symbols used Fault messages In the documentation 1.1.1 Warning notices - Structure and Emptying the ACS 810 meaning 10.1 Automatic emptying 1.1.2 Symbols in this documentation 10.2 Extraction of internal refrigerant circuit with...

  • Page 3: Symbols Used

    Symbols used | ACS 810 | 3 | Symbols used Calibration 13.1 Internal refrigerant cylinder scale In the documentation 13.2 Tara values 13.3 Pressure sensor 1.1.1 Warning notices - Structure and meaning 13.3.1 Checking the adjustment Warning notices warn of dangers to the user or 13.3.2 Adjusting the pressure sensor...

  • Page 4: Important Information

    | 4 | ACS 810 | Important information Important information Test equipment and auxiliary materials Installation and/or repairs must only be performed by trained and instructed Bosch customer service representatives or companies authorized by Bosch General tools for electricians and A/C mechanics If the units are opened or modified by unauthorized Digital multimeter (e.g.

  • Page 5: Safety Regulations

    Before connecting the ACS 810 to a vehicle air Never open or damage high-voltage batteries. conditioning system or an external refrigerant...

  • Page 6: Notes On Operation

    ACS 810 unattended when in operation. For safety reasons it is advisable to use a residual Position the ACS 810 on all four wheels on a flat, current operated circuit breaker (rccb) with the vibration-proof surface such that proper operation following specifications: of the scales is guaranteed.

  • Page 7: Product Description

    Product description | ACS 810 | 7 | Product description 5.1.2 Rear view Description of unit 5.1.1 Front view Fig. 2: Rear view 1 Service quick-release coupling (LP) 2 Service quick-release coupling (HP) 3 Service hose (5 m) 4 Service hose mount...

  • Page 8: Display And Control Panel

    Terminate and return. For updating firmware/software or database Various functions are assigned to the <MENU> function key in the ACS 810 software. The functions of the keys are defined in the menu line of the ACS 810 software. 5.1.5 Input keys The input keys can be used to enter letters, numbers and special characters in the input boxes.

  • Page 9: Program Structure

    Program structure | ACS 810 | 9 | Program structure Manual mode Input Menu Calibration and tare SELECT PORTS Input Menu TANK CALIBRATION <RECOVERY> IN OIL CALIBRATION R Automatic emptying + < > 1111 R Extraction 2. Enter OUT OIL CALIBRATION R Oil drain 3.

  • Page 10: Hydraulics Diagram

    | 10 | ACS 810 | Hydraulics diagram Hydraulics diagram HIGH EV10 Des. Description Des. Description Combi filter Fresh oil tank Vacuum pump Oil non-return valve Expansion valve Vacuum solenoid valve Evaporator/oil separator Flow solenoid valve Compressor oil separator Recovery solenoid valve...

  • Page 11: Service Phases

    1. The ACS 810 is connected to the vehicle with the At the end of this phase, the solenoid valves EV10, service hoses T1 and T2.
  • Page 12 | 12 | ACS 810 | Service phases HIGH EV10 Des. Description Des. Description Fresh oil tank Combi filter Vacuum pump Oil non-return valve Expansion valve Vacuum solenoid valve Evaporator/oil separator Flow solenoid valve Recovery solenoid valve Compressor oil separator...

  • Page 13: Draining Oil Into The Used Oil Bottle

    Service phases | ACS 810 | 13 | Draining oil into the used oil bottle At the end of recovery, the solenoid valve EV7 opens and the oil previously separated out in the evaporator/ oil separator (4) drains into the used oil bottle (9).

  • Page 14: Vacuum Phase

    1. The ACS 810 is connected to the vehicle with the service hoses T1 and T2. 2. Open the service quick-release coupling valves. 3. Press the <Vacuum>...
  • Page 15 Service phases | ACS 810 | 15 | HIGH EV10 Des. Description Des. Description Fresh oil tank Combi filter Vacuum pump Oil non-return valve Expansion valve Vacuum solenoid valve Evaporator/oil separator Flow solenoid valve Recovery solenoid valve Compressor oil separator...

  • Page 16: Leak Test

    | 16 | ACS 810 | Service phases Leak test If the pressure at P1 falls below the value saved in the software during the leak test, an error message The leak test starts after the vacuum phase. is displayed.

  • Page 17: Refrigerant Preparation

    EV5 and EV6 are opened and the compressor (6) starts. Internal preparation of the refrigerant is the same process that the ACS 810 performs in the recovery phase to clean the refrigerant recovered from the HIGH vehicle air conditioning system.

  • Page 18: Fresh Oil Filling

    | 18 | ACS 810 | Service phases Fresh oil filling 1. Open valve of service quick coupler T2. 2. Open HP valve. You can only fill new fresh oil into a vehicle A/C 3. Open solenoid valve EV8.  The pressure difference makes fresh oil in the system, if there is vacuum inside the A/C system.

  • Page 19: Filling Refrigerant

    Service phases | ACS 810 | 19 | Filling refrigerant 1. Press the key  EV3, EV6 and EV10 are opened. The refrigerant in the internal refrigerant cylinder is  Refrigerant pump (11) will start. used for filling the vehicle air conditioning system.

  • Page 20: Separating And Returning Compressor Oil

    | 20 | ACS 810 | Service phases Separating and returning This oil is separated from the refrigerant in the compressor oil compressor oil separator (5) and is then fed back to the compressor (6). During the recovery phase and preparation of the refrigerant, small quantities of compressor oil get into the internal circuit.

  • Page 21: Non-Condensing Gases

    Service phases | ACS 810 | 21 | Non-condensing gases The pressure of the internal refrigerant cylinder increases during the recovery phase and when The drain valve (V6) for non-condensing gases preparing the refrigerant. opens if the pressure in the refrigerant cylinder...

  • Page 22: Troubleshooting

    Actions HIGH PRESSURE There is excess pressure at the outlet of the compressor. Turn off the ACS 810 and wait approx. 30 minutes. PROGRAM ERROR Error in the software. FULL TANK The internal refrigerant cylinder has been filled to maximum filling level.

  • Page 23: 10. Emptying The Acs 810

    Emptying the ACS 810 | ACS 810 | 23 | 10. Emptying the ACS 810 10.2 Extraction of internal refrigerant circuit with second A/C service unit When repairing internal components, we recommend extracting the internal hoses on the If recovery cannot be performed due to a defective...

  • Page 24: Troubleshooting And Analysis

    4. Check compressor (6). Before carrying out any service intervention, reduce the ACS 810 pressure so that no refrigerant is ACS 810 ends the recovery phase but the pressure at released. the pressure gages does not change. 1. Valves V1, V2, V3, and V4 must be open.

  • Page 25: Fault Messages That Can Occur During Recovery

    TROUBLESHOOTING AND ANALYSIS | ACS 810 | 25 | 11.2 Faults during the vacuum phase 11.1.3 Fault messages that can occur during recovery 11.2.1 The vacuum pump starts "CYLINDER FULL" The vacuum pump starts but no vacuum is generated in the vehicle air conditioning system...

  • Page 26: Fault Message That Can Occur During The Vacuum Phase

    | 26 | ACS 810 | TROUBLESHOOTING AND ANALYSIS 11.5 Faults during filling with refrigerant 11.2.3 Fault message that can occur during the vacuum phase 11.5.1 Vehicle air conditioning system cannot be "A/C SYSTEM FULL" filled If the refrigerant pump works, but does not charge the ¶...

  • Page 27: Component Test And Maintenance

    Component test and maintenance | ACS 810 | 27 | 12. Component test and 12.3 Pressure switch P2 maintenance The pressure switch is normally closed between contacts 1 and 2, and open between contacts 1 12.1 Vacuum pump and 4. The pressure switch opens at 16 bar.

  • Page 28: Periodic Check Of The Non-Condensable Gas Purge Valve

    | 28 | ACS 810 | Component test and maintenance 12.5 Periodic check of the non-condensable 12.6 Combo filter gas purge valve 12.6.1 Replacement of combo filter CAUTION: Only qualified technicians who DANGER – Risk of electric shock from are authorized to use refrigerants may dangerous voltage! carry out this procedure.

  • Page 29: Reset Filter

    Component test and maintenance | ACS 810 | 29 | 4. Close the HP and LP valves on the display and 12.6.2 Reset filter control panel. 5. Switch off ACS 810. Observe the ACS 810 menu prompting. 6. Disconnect ACS 810 from power supply.

  • Page 30: Vacuum Pump

    | 30 | ACS 810 | Component test and maintenance 12.7 Vacuum pump Do not use excessive force when securing and 12.7.1 Changing vacuum pump oil removing the oil drain and oil filling screw. The container for catching oil should have a DANGER –...

  • Page 31: 13. Calibration

    Calibration | ACS 810 | 31 | 13. Calibration 13.2 Tara values The following Tara values for the Internal refrigerant 13.1 Internal refrigerant cylinder scale cylinder is set from the factory. Detach the rear panel and remove the refrigerant Internal refrigerant cylinder: cylinder from the scale.

  • Page 32: Pressure Sensor

    3. Start the vacuum function and maintain the vacuum 5. Remove the service hoses on the ACS 810 and in the hoses for 5 minutes (this subjects the open the HP and LP valves on the front panel pressure sensor to a vacuum).

  • Page 33: 14. Component Test

    Component test | ACS 810 | 33 | 14. Component test 14.3 Control PCB input signal 14.1 Follow the additional ACS 810 menu prompting. Follow the additional ACS 810 menu prompting. 1. Call up the start screen. 2. Press <3> and <Flush> simultaneously and release.

  • Page 34: Counter

    | 34 | ACS 810 | Component test 14.5 Counter 14.7 Draining oil Displays the following information: Prepared refrigerant This function opens the solenoid valve EV7 and ACS 810 operating hours, drains the pressure in the compressor. This enables Vacuum pump operating hours the solenoid valve EV7 to be serviced.

  • Page 35: 15. Changing Basic Settings

    Changing basic settings | ACS 810 | 35 | 15. Changing basic settings 1. Call up the start screen. 2. Press <3> and <Flush> simultaneously and release.  The message ENTER CODE 0000 The set values guarantee that the ACS 810 will is displayed.

  • Page 36: 16. Software

    3. Press and hold the <MENU> key. 5. Remove plastic cover (input PS2 stick) between 4. Turn on the ACS 810 and release the <MENU> key. menu key and stop key. 5. The ACS 810 turns itself off after programming.

  • Page 37: 17. Circuit Diagram

    Circuit diagram | ACS 810 | 37 | 17. Circuit diagram 17.1 Control PCB Fig. 7: Control PCB Fig. 8: Control PCB Robert Bosch GmbH 1 689 975 253 2021-01-26...

  • Page 38: Computer Printed Circuit Board

    | 38 | ACS 810 | Circuit diagram 17.2 Computer printed circuit board Fig. 9: Computer printed circuit board 1 Internal refrigerant scale connection 2 Printer power supply connection 3 Not used 4 Not used 5 Pressure sensor connection 6 Internal printer connection...
  • Page 40 Robert Bosch GmbH Automotive Service Solutions www.boschaftermarket.com Franz-Oechsle-Straße 4 73207 Plochingen DEUTSCHLAND bosch.prueftechnik@bosch.com http://www.downloads.bosch-automotive.com 1 689 975 253 | 2021-01-26...

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