Plumbing And Mechanical System Operation; Compressor; Vacuum Pump; Manifold Assembly - Bosch ACS 561 Repair Instructions

Plumbing and Mechanical
Plumbing and Mechanical System
Operation
The plumbing and mechanical system is con-
trolled by electrical impulses from the electrical
system. There are five main components to the
plumbing system:

• Compressor

• Vacuum Pump

• Panel Manifold Assembly

• Internal Storage Vessel (ISV)

Along with these components are several ancil-
lary components:

• Cooling Fan

• Bulkhead Oil Inject Assembly
• Oil Drain Bottle
• High and Low Side Gauges
• High (red) and Low (blue) Side Service
Hoses
All components are interconnected with vari-
ous lengths and diameters of flexible tubing or
copper tubing. The copper tubing is to connect
the compressor discharge port to the manifold
assembly. All lines connected to the compressor
are high pressure lines.
Compressor
The compressor is configured for R1234yf
refrigerant. When replacing the compressor,
heed the warnings, cautions, and any other
related safety information. For compressor
specifications, see General Information.
Vacuum Pump
The vacuum pump is used in this unit for the
recovery and vacuum processes. For vacuum
pump specifications, see General Information.
SP00D00517 2018-07-11

Manifold Assembly

The "top" or "panel" manifold assemblly consists
of the high- and low-side pressure gauges,
high- and low-side manually operated ball
valves, and three solenoids (S1, Recover; S2,
Vacuum; and S3, Charge). This unified as-
sembly permits efficient, reliable, operation of
the unit.
Unlike other units, this assembly does not have
the oil separator and filter/dryer attached to
it.This manifold assembly is not interchange-
able with any other manifold assemblies. Repair
or replacement of the manifold should be per-
formed under clean conditions so particulates
do not enter the assembly from any open ports.
Particulates can clog the small chambers and
cause solenoid and check valve malfunctions,
as well as contaminate a vehicle air condition-
ing system.
Internal Storage Vessel (ISV)
The ISV stores the refrigerant from the vehicle
A/C system and from the external refrigerant
source tank. It is important to note that if the
external source tank is always connected to the
unit, the unit will make sure the required amount
of refrigerant is always in the ISV through the
"Tank Fill" function which will run in the back-
ground whenever the unit is in use.
Ancillary components and assemblies included
are:
Cooling Fan: The cooling fan is necessary to
keep the compressor below its maximum am-
bient operation temperature of 50°C (140°F)
or less. The fan is also used to prevent build
up of refrigerant in the cabinet and prevent
fire. Attached to the cooling fan is a small fan
which is used as an airflow sensor. If the cool-
ing fan is not operating, the airflow sensor will
not turn, and thus a signal will not be sent to
the control board. When this happens, the unit
will not operate.
Bulkhead Oil Inject Block Assembly: This
assembly serves as the attachment ports for
the high- and low-side service hoses and as
the oil injection point through the Oil Inject
Solenoid (S5).
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ACS 561 Service Manual
Robert Bosch GmbH