Bosch ACS 611 Original Instructions Manual

ACS 611

Originalbetriebsanleitung

Klimaservicegerät

Original instructions

A/C service-unit

Notice originale

Appareil de SAV pour climatiseur

Manual original

Aparato de servicios de aire acondicionado

Istruzioni originali

Attrezzatura per assistenza climatizzatore

Bruksanvisning i original

A/C serviceenhet

Oorspronkelijke gebruiksaanwijzing

Airco-onderhoudsapparaat

Manual original

Aparelho de manutenção de sistemas de ar condicionado

Alkuperäiset ohjeet

A/C huoltolaite

Original brugsanvisning

A/C tjenesten Unit

Original driftsinstruks

A/C tjenesten Unit

Oryginalna instrukcja eksploatacji

Urządzenie do obsługi układu klimatyzacji

Původní návod k používání

Přístroj na servis klimatizací vozidel

Orijinal işletme talimatı

A/C servis ünitesi

Оригинальное руководство по эксплуатации

Подготовка к обслуживанию

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32 | ACS 611 |

1. Symbols used 34

1.1 In the documentation 34

1.1.1 Warning notices Structure and meaning 34

1.1.2 Symbols in this documentation 34

1.2 On the product 34

2. Important notes 34

2.1 User group 34

2.2 Agreement 34

2.3 Obligation of contractor 35

2.4 Safety regulations 36

2.5 Safety devices 37

3. Product description 38

3.1 Application 38

3.2 Delivery speciﬁcation 38

3.3 Overview on software texts 38

3.4 Description of unit 39

3.4.1 Selection and function keys 40

3.4.2 Input keys 41

3.4.3 Printer 41

3.4.4 Service ﬂap 41

3.4.5 Scales for refrigerant, fresh oil and used oil 41

3.4.6 Service hose and service quick-release coupling 42

3.4.7 Locking brakes 42

3.4.8 Power cord 42

3.4.9 Master switch 42

3.5 Description of function 42

4. Program structure 43

4.1 Calibration and tare 43

4.2 Settings 43

4.3 Repair 43

4.4 Vehicle and customer data 43

4.5 Menu 43

4.6 Manual mode 43

4.7 Automatic mode 43

4.8 Flush (optional) 43

4.9 Enter 43

5. Initial commissioning 44

5.1 Removing transportation packaging 44

5.2 Switching on the ACS 611 44

5.3 Required settings 44

5.3.1 Setting the language 44

5.3.2 Setting the date and time 44

5.3.3 Set workshop data 45

5.3.4 Enter serial number 45

5.4 Internal Refrigerant cylinder 45

5.4.1 Checking type of connection of external refrigerant cylinder 45

5.4.2 Filling internal refrigerant cylinder 46

6. A/C service preparation 46

7. Operating instructions 47

7.1 Database 47

7.1.1 Vehicle database 47

7.1.2 Personal database 47

7.1.3 Customer and vehicle data 47

7.2 Service phases 47

7.3 Manual service 48

7.3.1 Filling of refrigerant, fresh oil and UV dye 48

7.3.2 Recovery 49

7.3.3 Vacuum 49

7.4 Automatic service 49

7.5 Processing 50

8. Troubleshooting 51

8.1 Service prompt 51

8.2 Fault messages 51

9. Diagnosis 52

9.1 Preparatory work 52

9.2 Diagnosis 52

10. ACS 611 settings 53

10.1 Set unit 53

10.2 Set length of service hoses 53

10.3 Contrast 53

10.4 Flush (optional) 53

10.5 Scales for fresh and used oil 53

10.6 UV dye 53

10.7 Service data report 54

10.7.1 Activate/deactivate consumption R134a report 54

10.7.2 Report printout 54

Contents English

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11. Maintenance 54

11.1 Spare and wearing parts 54

11.2 Maintenance interval 54

11.3 Tare oil scales 55

11.4 Calibration of scales 55

11.4.1 Calibrating internal refrigerant cylinder 55

11.4.2 Fresh oil and used oil scales 55

11.5 Vacuum pump 56

11.5.1 Changing vacuum pump oil 56

11.5.2 Reset of oil change interval 56

11.6 Combo ﬁlter 57

11.6.1 Replacement of combo ﬁlter 57

11.6.2 Reset ﬁlter 57

11.7 Software update 57

11.7.1 irmware 57

11.7.2 Vehicle database 58

11.8 Replacing printer paper 58

12. Disposal 58

12.1 Disposal of electronic parts 58

12.2 Disposal of LCD display 58

12.3 Disposal of refrigerants, UV dye, lubricants and oils 58

12.4 Disposal of combo ﬁlter 58

13. Technical data 59

13.1 ACS 611 59

13.2 Ambient temperature 59

13.3 Electromagnetic compatibility 59

14. Glossary 59

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34 | ACS 611 | Symbols used

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 consequences 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 failure 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-observance:

Key word Probability of

occurrence

Severity of danger if instructions not observed

DANGER Immediate impending

danger

Death or severe injury

WARNING 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.

Information Practical hints and other

useful information.

Multi-step operation

Instruction consisting of several steps.

One-step operation

Instruction consisting of one step.



Intermediate result

An instruction produces a visible intermediate result.

Final result There is a visible final result on

completion of the instruction.

1.2 On the product

Observe all warning notices on products and ensure they remain legible.

2. Important notes

Before start up, connecting and operating

Bosch products it is absolutely essential that the operating instructions/owner’s

manual and, in particular, the safety instructions are studied carefully. By doing so you can eliminate any uncertainties in handling Bosch products and thus associated safety risks upfront; something which is in the interests of your own safety and will ultimately help avoid damage to the device. When a Bosch product is handed over to another person, not only the operating instructions but also the safety instructions and information on its designated use must be handed over to the person.

2.1 User group

The product may be used by skilled and instructed personnel only. Personnel scheduled to be trained, familiarized, instructed or to take part in a general training course may only work with the product under the supervision of an experienced person. All work conducted on pressurized equipment may be performed by persons with sufficient knowledge and experience in the field of refrigeration, cooling systems and coolants and, also be aware of the risks involved in the use of pressurized devices.

2.2 Agreement

By using the product you agree to the following regulations:

Software and data are the property of Robert Bosch GmbH or its suppliers and protected against copying by copyright laws, international agreements and other national legal regulations. Copying or selling of data and software or any part thereof is impermissible and punishable; in the event of any infringements Bosch reserves the right to proceed with criminal prosecution and to claim for damages.

¶ Wear safety goggles.

¶ Wear protective gloves.

¶ Protect against dampness and moisture.

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2.3 Obligation of contractor

The contractor is obliged to ensure that all measures geared towards the prevention of accidents, industrial diseases, labor-related health risks are taken and measures towards making the workplace fit for people to work in are carried out.

Specifications for electrical systems (BGV A3)

Electrical engineering in Germany is subject to the accident prevention regulations of the trade association "Electrical Plant and Equipment as under BGV A3 (previously VBG 4)". In all other countries, the applicable national regulations acts or decrees are to be adhered to.

Liability

All data in this program is based - where possible - on manufacturer and importer details. Bosch does not accept liability for the correctness and completeness of software and data; liability for damage caused by faulty software and data is ruled out. Whatever the event, Bosch liability is restricted to the amount for which the customer actually pays for this product. This disclaimer of liability does not apply to damages caused by intent or gross negligence on the part of Bosch.

Warranty

Any use of non-approved hardware and software will result in a modification to our product and thus to exclusion of any liability and warranty, even if the hardware or software has in the meantime been removed or deleted.

No changes may be made to our products. Our products may only be used in combination with original accessories and original service parts. Failing to do so, will render null and void all warranty claims.

This product may only be operated using Bosch approved operating systems. If the product is operated using an operating system other than the approved one, then our warranty obligation pursuant to our supply conditions will be rendered null and void. Furthermore, we will not be held liable for damage and consequential damage incurred through the use of a non-approved operating system.

Basic rules

The contractor is bound to ensure that all electrical equipment and operating material is set up, modified and maintained by skilled electricians only or under the guidance and supervision of a skilled electrician in accordance with electrical engineering principles.

Furthermore, the contractor must ensure that all electrical equipment and operating material is operated in keeping with electrical engineering principles.

If a piece of electrical equipment or operating material is found to be defective, i.e. it does not or no longer complies with electrical engineering principles, the contractor must ensure that the fault is rectified immediately and, in the event that imminent danger exists, also ensure that the electrical equipment or the electrical operating material is not used.

Tests (taking Germany as an example):

R The contractor must ensure that all electrical

systems and equipment are tested by a qualified electrician or under the guidance of a qualified electrician to ensure they are in proper working order:

$ Before starting for the first time. $ After modification or repair before starting for the

first time.

$ At given intervals. Set intervals such as to ensure

that faults that can be expected to occur are determined in good time.

R The test is to take the electrical engineering

principles relating hereto into account.

R Upon request of the trade association, a test manual

is to be maintained into which specific entries are made.

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2.4 Safety regulations

Always carefully read and observe all the safety regulations before using the Bosch product.

Avoid all skin contact with the refrigerant. The low boiling point of the refrigerant (approx. -30 °C) can lead to frostbites. Should it nevertheless come into contact with the skin, remove any moistened clothing immediately and rinse the affected skin with copious amounts of water.

R Avoid all skin contact with the UV dye. Should

it nevertheless come into contact with the skin, remove any moistened clothing immediately and rinse the affected skin with copious amounts of water.

R R134a is colorless, has a weak intrinsic odor and

is heavier than air. It displaces oxygen and may flow into repair pits. Should refrigerant escape (malfunction), always ensure adequate ventilation and air extraction (especially in pits). Exit the workshop.

Never inhale refrigerant, dye and oil vapors. The vapors can irritate the eyes, nose and respiratory system. If liquid refrigerant or 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.

R Never swallow UV dye. If swallowed inadvertently,

never attempt to induce vomiting. Drink copious amounts of water and obtain medical help.

R Before connecting the ACS 611 to a vehicle air

conditioner or an external refrigerant cylinder, make sure the quick-release couplings are not leaking. Only ever use external refrigerant cylinders provided with safety valves and certified in line with the applicable standards.

R Before switching off the ACS 611, make sure all

filling and drainage operations have been completed. This prevents refrigerant escaping into the environment.

Never use compressed air with R134a. Certain mixtures of air and R134a are highly flammable. Such mixtures are a potential hazard and may lead to fire or explosions and thus cause damage or injury.

R Refrigerant extracted from a vehicle air conditioner

may be contaminated with moisture, lubricant, dirt and traces of other gases.

R R134a is not to be used in areas in which there is a

danger of explosion. Fire, naked flames and smoking are prohibited. Welding and soldering are not permitted.

R High temperatures and UV radiation may chemically

separate the R134a. The resultant products cause coughing and nausea.

R R134a is not to be mixed with other refrigerants.

Themixing of refrigerants could damage the vehicle air conditioner.

If high-voltage components or high-voltage wires are inappropriately handled, there is a risk of fatal injury from high voltages and the possible transmission of current through the body.

R De-energization is only to be performed by a

qualified electrician, a qualified electrician for specific tasks (hybrid), or a power systems engineer.

R Work 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".

R Even after deactivating the high-voltage vehicle

electrical system, the high-voltage battery may still be live.

R The operating condition cannot be established from

any running noise, as the electric machine is silent when stationary.

R In gear positions "P" and "N" the engine or electric

motor may start spontaneously depending on the charge of the high-voltage battery.

R Never open or damage high-voltage batteries. R On accident vehicles, never touch high-voltage

components or exposed high-voltage wires before deactivating the high-voltage vehicle electrical system.

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R The ACS 611 must be constantly monitored when

in operation. Never leave the ACS 611 unattended when in operation.

R The vehicle A/C service using the ACS 611 must

be prepared and implemented so that the vehicle air conditioner circuit does not have to be opened (forexample by removing the radiator or engine).

R Position the ACS 611 on all four wheels on a flat,

vibration-proof surface so that proper operation ofthe scales is guaranteed.

R The ACS 611 can be secured in position by locking

the brake.

R The ACS 611 must always be transported in its

operating position. Never lay the ACS 611 on its side, as oil could then escape from the vacuum pump, or the built-in compressor could be damaged.

R There are no additional safety systems for protecting

the ACS 611 against damage resulting from natural catastrophes.

R Never remove any components from inside the

ACS 611 except for maintenance or repair purposes.

R Observe the pertinent legal regulations or directives

to ensure safe handling of pressurized devices.

R We recommend calibrating the scales and pressure

sensors at least once per year. Contact customer service for calibrating the scales of the internal refrigerant cylinder.

R Never perform any maintenance work which is not

expressly recommended in this manual. Contact customer service if components have to be replaced other than in the course of maintenance work.

R ACS 611 must be connected to a properly grounded

electrical connection.

R If damage to the ACS 611 is established, terminate

usage immediately and contact customer service.

R The service hoses and quick-release couplings

must be regularly checked for wear and replaced ifdamaged.

R The ACS 611 must be operated in an environment

corresponding to the directive BGR 157 with respect to the exchange of air.

R Observe local laws or directives so as to ensure the

safety of the pressurized device.

R For safety reasons it is advisable to use a residual

current operated circuit breaker (rccb) with the following specifications:

Parameters Specification

Rated voltage

230 VAC ± 10 %

Rated frequency

50/60 Hz Rated current 230 VAC 6,3 A Rated tripping current

30 mA Tripping switch

2.5 Safety devices

Description Operation

Pressure switch Switches the compressor off if the normal

operating pressure is exceeded.

Safety valve The safety valve opens if the design

pressure is exceeded.

Fuse

Interrupts the power supply if overcurrent is applied to the ACS 611.

Vents

The ACS 611 is provided with vents in the bottom of the housing to ensure the exchange of air even when switched off.

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38 | ACS 611 | Product description

3. Product description

3.1 Application

ACS 611 is suitable for vehicles with conventional combustion engines (PAG oil) as well as for hybrid and electric vehicles (POE oil). ACS 611 features all functions necessary for the air conditioning service of vehicles.

! ACS 611 can be operated with either PAG or POE

oil. Mixing the oils causes damage to the vehicle air conditioning system. For this reason, the oil types must not be changed after the first vehicle air conditioning service.

The following functions can be implemented:

R Refrigerant removal by suction and filling. R Refrigerant processing. R Vacuum creation. R Addition of oil. R Addition of UV dye. R Flushing.

! The ACS 611 is only to be operated with R134a

refrigerant. The ACS 611 is not to be used for service work on vehicles with air conditioning systems employing refrigerants other than R134a, as this will cause damage. Check the type of refrigerant used in the vehicle air conditioner prior to A/C service.

3.2 Delivery specification

Description Order number

ACS 611 – Safety goggles

–

Protective gloves

–

Original instructions

SP00D00002

External refrigerant cylinder adapter set big small

SP00100019 SP00100080

Pre-assembled.

3.3 Overview on software texts

Software Orig. operating instructions

UV DYE

UV dye

HOSES LENGTH

Service hose length

TANK

Internal refrigerant cylinder IN OIL Fresh oil OIL OUT Used oil HOSES

Service hoses SELECT PORTS

Vehicle air-conditioning system

service connection (service quick-

release coupling) CHANGE OIL

Vacuum pump

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Product description | ACS 611 | 39

Fig. 2: Rear

1 Service quick-release coupling (high pressure) 2 Service quick-release coupling (low pressure) 3 Service hose (2,5m/5m)1) 4 Service hose mount 5 Rear wheels 6 Master switch 7 Power cord (socket)

Depending on version ordered

3.4 Description of unit

Fig. 1: Front view

1 Valve high pressure (hp) 2 Valve low pressure (lp) 3 Printer 4 Display and control panel 5 Gauge low pressure (lp) 6 Gauge high pressure (hp) 7 Pressure gauge of internal refrigerant cylinder 8 Fresh oil bottle 9 UV dye bottle 10 Used oil bottle 11 Cover 12 Front wheels with locking brake

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